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Baumuller b maXX BM4400 Manual

Baumuller b maXX BM4400 Manual

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b maXX
BM4400
Basic unit
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5.04043.06

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Summary of Contents for Baumuller b maXX BM4400

  • Page 1 ® b maXX BM4400 Basic unit Manual 5.04043.06...
  • Page 2 Title Manual ® Product b maXX BM4400 Version 5.04043.06 Part No. 384209 Status 13.11.2007 Copyright These operating instructions may be copied by the owner in any quantity but only for internal use. For other purposes these operating instructions and extracts thereof must not be copied or reproduced.

  • Page 3: Table Of Contents

    Table of contents Introduction ............. . Validity of this manual .
  • Page 4 Table of contents Mounting ..............37 General safety instructions.
  • Page 5 Table of contents Maintenance ............Safety instructions .
  • Page 6 Table of contents D.13 Electrical data - BM442X power module ........186 D.14 Electrical data - BM443X power module .
  • Page 7 Table of contents Appendix E - Safe stop ............221 Methods to avoid an unexpected starting .
  • Page 8 Table of contents ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 9: Introduction

    NTRODUCTION ® This manual is an important part of your b maXX BM4400 appliance; Please, therefore completely read this manual, before starting operation, last but not least on behalf of your own security. In this chapter we describe the first steps, which have to be done after you have received the device.

  • Page 10: First Steps

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

  • Page 11: Fundamental Safety Instructions

    UNDAMENTAL SAFETY INSTRUCTIONS General notes In this chapter dangers are described, arising when working with the Baumüller-device. Dangers are pointed up with symbols (icons). All symbols that are used in this manual are listed and explained. How you can protect yourself against the single dangers in the concrete case, we will not explain in this chapter.

  • Page 12: Hazard Information And Commands

    Hazard information and commands Hazard information and commands Each hazard is classified in one of three different hazard classes. Every hazard class has one of the following characteristic signal words: DANGER m serious property damage m serious personal injury m death - will occur WARNING m serious property damage m serious personal injury m death - may occur CAUTION...

  • Page 13: Fundamental Safety Instructions

    Fundamental safety instructions 2.2.1 Hazard information structure The following two examples show you how the hazard informations are constructed. The triangle is used when indicating a hazard for human beings. When there is a circle instead of the triangle, the hazard information is only for possible property damage. A triangle indicates hazard for human beings.

  • Page 14: Hazard Information On Personal Injury

    Hazard information and commands 2.2.2.1 Hazard information on personal injury To distinguish each class of hazard information, we use a characteristic outline for both the triangular hazard signs and the square-form icons For the hazard class DANGER the danger sign is used. The hazard information of this hazard class used in this documentation is listed below: DANGER The following will occur, if you do not observe this danger information:...
  • Page 15 Fundamental safety instructions For the hazard class WARNING the warning sign is used. The following hazard infor- mation of this hazard class is used in this documentation. WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death The hazard is: electricity.
  • Page 16 Hazard information and commands WARNING The following may occur, if you do not observe this warning information: m serious personal injury m death The hazard is: liquid coolant. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard. ®...
  • Page 17 Fundamental safety instructions For the hazard class CAUTION the caution sign is used when there is hazard for per- sons or of environmental pollution. The following hazard information of this hazard class is used in this documentation. CAUTION The following may occur, if you do not observe this caution information: m minor to medium personal injury.
  • Page 18 Hazard information and commands CAUTION The following may occur, if you do not observe this caution information: m minor to medium personal injury. The hazard is: noise. Here the hazard may be described in detail. Here is described what you can do to avoid the hazard. CAUTION The following may occur, if you do not observe this caution information: m minor to medium personal injury.

  • Page 19: Hazard Information On Property Damage

    Fundamental safety instructions 2.2.2.2 Hazard information on property damage If there is a round caution sign in front of the signal word, the safety information refers to property damage. CAUTION The following may occur, if you do not observe this caution information: m property damage.

  • Page 20: Information Sign

    Information sign Information sign NOTE This note is a very important information. Legal instructions This documentation is addressed to technical qualified personnel, who is specifically skilled and who is thoroughly familiar with all warnings and maintenance procedures. The devices are made according to the state-of-the-art technology and are fail-safe. They can be installed safe, can be put into operation and they function without problems, if it is assured, that the instructions of the documentation are followed.

  • Page 21: Inappropriate Use

    Fundamental safety instructions (cable-guided and blasted) special measures must be provided for and must be proved by the control cabinet manufacturer, because EMC-interferences can occur, if no ad- ditional measures have been taken. If a device, which was described here, reaches the category C2/C1, even with additional measures, can not be ensured.

  • Page 22: Safety Equipment

    Safety equipment Safety equipment The devices BM441X, BM442X and BM443X comply with the protection class IP 20. The devices BM443X and BM444X comply with the protection class IP20, if the power con- nections are performed safe-to-touch according to IP20, otherwise IP10. BM445X, BM446X and BM447X comply with the protection class IP 00.

  • Page 23: Safety Precautions In Normal Operation

    Fundamental safety instructions Safety precautions in normal operation h at the location of your appliance regard the safety regulations for the plant, into which the appliance has been built in. h if safety regulations require additional monitoring or safety devices supply your appli- ance with them.

  • Page 24: Responsibility And Liability

    2.13 Responsibility and liability 2.13 Responsibility and liability To be able to work as safe as possible with this device, you must know and follow the danger notes as well as the safety instructions. 2.13.1 Observing the safety notes and safety instructions In this manual we use visually unified safety instructions, which are intended to prevent from personal injury or damage to property.

  • Page 25: Transportation And Packing

    RANSPORTATION AND PACKING In this chapter we describe, which conditions have to be adhered to at transportation, how you check the device after receipt and what you should have to consider, if you dispose the packing. To be considered by transportation For the first transportation of the device, the device was packed in the manufacturer com- pany.

  • Page 26: Dispose Packing

    Dispose packing WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Do not operate the device, if you have recognized a transportation damage or if you assume this. In this case immediately contact Baumüller Nürnberg GmbH If there is no transportation damage recognizable: h Open the packing of the device.

  • Page 27: Description Of The Devices

    ESCRIPTION OF THE DEVICES ® In this chapter the basic construction of the devices b maXX BM4400 and the slots of the controller cartridge are described and the type key on the devices is explained. NOTE ® The devices of the b maXX BM4400-series are provided for the operation in the ’second en- vironment’...

  • Page 28: Structure

    Structure Structure ® The devices of the b maXX -series are servo converters of Baumüller Nürnberg GmbH. The devices consist of a power unit with an integrated slot for the controller cartridge (nar- row or wide). The controller cartridge itself possess, besides a firmly installed controller (slot F), rows of slots, that can be filled with optional modules.

  • Page 29: Controller Unit Versions

    Description of the devices Controller unit versions There are three versions of the controller unit: This version is a 1-row equipped single row This version is a 1-row equipped controller unit in a 2-rowed installa- controller unit in a 3-rowed instal- tion space.

  • Page 30: Slots

    Controller unit versions 4.2.1 Slots In slots of the controller unit functional- or optional modules are plugged, which extend the functional range of the controller unit. Every slot is clearly identified by a code letter. A The controller communicates via a functional module bus with plug-in modules in these slots.

  • Page 31: Combination Possibilities Plug-In Module-Controller Slots

    Description of the devices 4.2.1.1 Combination possibilities plug-in module-controller slots Function modules Option modules Controller unit, permanently installed preferred slot Baumüllter Nürnberg GmbH recommends, in order to reach the highest functional range, to insert the plug-in modules into these slots. possible slot only if the preffered slot is occupied, we recommend in order to reach the highest functional range, to insert the plug-in modules into this slot.

  • Page 32: Interconnect The Devices

    Interconnect the devices Interconnect the devices ® The device is part of the Baumüller series b maXX BM4400 and can be connected to- gether with other Baumüller devices. Overview of dangerous areas The following overview shows the existing danger areas on the particular device. Use this survey for an overview of the existing danger areas, if you incorporate into the handling of this device.
  • Page 33 Description of the devices Figure 4: Danger areas BM445X, BM446X and BM447X ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 34: Marking Of The Device - Type Key

    Marking of the device - type key Marking of the device - type key On the type plate (label) you will find, besides others, the type key of the device. Figure 5: Position of type key label ® Manual b maXX BM4400 Document No.
  • Page 35 Description of the devices The type key has the form: BM4XXX - XXX - XXXXX[Ryy] - XX. Directly behind the type key is the design code (-XXXX - X - XXX - XXX). In the following table the type key is explained. BM4XXX - XXX - XXXXX[Ryy] - XX Device generation BM4XXX - XXX - XXXXX[Ryy] - XX...
  • Page 36 Marking of the device - type key BM4XXX - XXX - XXXXX[Ryy] - XX Optional chopper resistor R16: Chopper resistor with 16 Ω R10: Chopper resistor with 10 Ω R05: Chopper resistor with 5 Ω R03: Chopper resistor with 3 Ω BM4XXX - XXX - XXXXX[Ryy] - XX State of software controller (firmware) 01: Series version 1.x...

  • Page 37: Mounting

    OUNTING In this chapter we describe the mechanical mounting of the device into a control cabinet. Data about the installation space is available in this manual (see ZInstallation space– from page 39). Mounting consists of the following steps: 1 Prepare mounting (drill holes/cut-out segments) 2 Install device WARNING The following may occur, if you do not observe this warning information:...

  • Page 38: Requirements To The Executing Personnel

    Requirements to the executing personnel h Pay attention to all areas at the device, which could be dangerous for you while mount- ing. Use this survey only for the mechanical mounting. Dangers, which, for example, result from electricity are not shown here. Figure 6: Danger areas by the mechanical mounting Requirements to the executing personnel...

  • Page 39: Prepare Mounting

    Mounting Prepare mounting You can prepare the mounting with the configuring manual for your installation. With the project manual and the drill figures (see ZDrilling patterns– from page 49) you can deter- mine the dimensions for the cut-outs and for the fastening drills. CAUTION The following can occur, if you disregard this warning instruction: m minor to medium personal injury.

  • Page 40: Installation Space Bm442X-S/A

    Installation space Figure 8: Installation space BM442X-S/A *: min. expansion space, also consider ZCooling– on page 165 Figure 9: Installation space BM442X-F *: min. Expansion space, also consider ZCooling– on page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 41: Installation Space Bm442X-C

    Mounting Figure 10: Installation space BM442X-C *: min. expansion space, also consider ZCooling– page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 42: Installation Space Bm443X-S/Z

    Installation space Figure 11: Installation space BM443X-S/Z *: min. expansion space, also consider ZCooling– on page 165 Figure 12: Installation space BM443X-A/F *: min. expansion space, also consider ZCooling– on page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 43: Installation Space Bm443X-C

    Mounting Figure 13: Installation space BM443X-C *: min. expansion space, also consider ZCooling– on page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 44: Installation Space Bm444X-S/Z

    Installation space Figure 14: Installation space BM444X-S/Z *: min. expansion space, also consider ZCooling– on page 165 Figure 15: Installation space BM444X-A/F *: min. expansion space, also consider ZCooling– on page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 45: Installation Space Bm445X-S/Z

    Mounting Figure 16: Installation space BM445X-S/Z *: min. expansion space, also consider ZCooling– on page 165 **: width inclusively bolt heads Figure 17: Installation space BM445X-A/F *: min. Expansion space, also consider ZCooling– on page 165 **: width inclusively bolt heads ®...

  • Page 46: Installation Space Bm446X-S/Z

    Installation space Figure 18: Installation space BM446X-S/Z *: min. expansion space, also consider ZCooling– on page 165 **: width inclusively bolt heads Figure 19: Installation space BM446X-A/F *: min. expansion space, also consider ZCooling– on page 165 **: width inclusively bolt heads ®...

  • Page 47: Installation Space Bm4-47X-F

    Mounting Figure 20: Installation space BM4-47X-F *: min. expansion space, also consider ZCooling– on page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 48: Installation Space Bm447X-A

    Installation space Figure 21: Installation space BM447X-A *: min. expansion space, also consider ZCooling– on page 165 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 49: Drilling Patterns

    Mounting Drilling patterns The following drawings show the drilling patterns of the devices. Use these drawings, to prepare the necessary drilling/cut-outs. Use the drawings under ZInstallation space– from page 39, to determine the required space in the control cabinet. Figure 22: Drilling pattern BM441X Figure 23: Drilling pattern BM442X...

  • Page 50: Drilling Pattern Bm443X

    Drilling patterns Figure 24: Drilling pattern BM443X Figure 25: Drilling pattern BM444X ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 51: Drilling Pattern Bm445X

    Mounting Figure 26: Drilling pattern BM445X Figure 27: Drilling pattern BM446X ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 52 Drilling patterns Figure 28: Drilling pattern BM447X-F ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 53: Mounting Instructions

    Mounting Figure 29: Drilling pattern BM447X-A Mounting instructions There are different mounting technics. Every mounting procedure is shown as a chart (see ZFigure 30– on page 55 to ZFigure 33– on page 58. Below the chart is the list of the devices, for which the particular instruction is to be used.
  • Page 54 Mounting instructions CAUTION The following may occur, if you disregard these safety notes: m minor to medium personal injury. The danger is: sharp edges. In case, while installing, you lift a device with unprotected hands, fingers/palm can be cut. If the device falls off, the feet can be cut. Wear safety gloves Wear safety shoes Complete the mounting in the following way:...

  • Page 55: Mounting Instruction Bm441X, Bm442X-S, Bm443X-S/Z, Bm444X-S/Z

    Mounting Figure 30: Mounting instruction BM441X, BM442X-S, BM443X-S/Z, BM444X-S/Z Device BM441X-XXX BM441X-XXX BM442X-S BM443X-S/Z BM444X-S/Z A - screws 2 x M5 4 x M5 4 x M5 4 x M5 4 x M5 B - washers 2 x (5.3 x 10) 4 x (5.3 x 10) 4 x (5.3 x 10) 4 x (5.3 x 10)
  • Page 56 Mounting instructions Figure 31: Mounting instruction BM445X-S/Z and BM446X-S/Z Device BM445X-S/Z BM446X-S/Z A - screws 4 x M8 4 x M8 B - washers 4 x (8.4 x 17) 4 x (8.4 x 17) c - mount spacing c = 7 mm c = 7 mm ®...
  • Page 57 Mounting Figure 32: Mounting instruction BM447X-A/F Device BM447X-S/A BM447X-F A - screws 38 x M6 22 x M6 B - spring washers 38 x DIN6796-6-FST 22 x DIN6796-6-FST C - washers 38 x (6.4 x 12.5) 22 x (6.4 x 12.5) ®...
  • Page 58 Mounting instructions Figure 33: Mounting instruction ’miscellaneous’ Device BM454X-A/F/Z/C BM443X-A/F/C BM444X-A/F BM445X-A/F BM446X-A/F A - screws 4 x M5 14 x M4 16 x M5 16 x M8 20 x M8 B - washers 4 x (5.3 x 10) 14 x (4.3 x 9) 16 x (5.3 x 15) 16 x (8.4 x 17) 20 x (8.4 x 17) WARNING...
  • Page 59 Mounting Type of protection: control cabinet with built in through-hole devices BM442X-A/F NOTE The following required control cabinet mounting is only valid for control cabinets with protec- tion class IP54 or higher. IP protection class for air-cooled through-hole devices: IP44 IP protection class for air-cooled through-hole devices: IP54 ®...
  • Page 60 Mounting instructions Figure 34: Control cabinet mounting BM442X-A/F ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 61: Connecting The Water Cooler

    Mounting Connecting the water cooler With water cooled devices (BM44XX-F and BM44XX-Z) you connect the coolant circula- tion before you install the electric. The water cooler has on its bottom side two pressfitting- transition pieces 15mm x R 1/2 ’ AG for flat washers. h Connect the cooling circulation to the water cooler.
  • Page 62 Connecting the water cooler ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 63: Installation

    NSTALLATION In this chapter we describe the electric installation of the device. The mechanical instal- lation is described in ZMounting– from page 37. Before installing assure, that the technical preconditions are fulfilled: 1 Check the requirements to the electrical mains and check if the existing mains is suit- able.

  • Page 64: Requirements To The Executing Personnel

    Requirements to the executing personnel Requirements to the executing personnel WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity.When operating with this electrical unit, inevitably certain parts of this unit are under dangerous voltage.

  • Page 65: Requirements To The Electrical Mains

    Installation Requirements to the electrical mains All important data is to be found in ZD.1 Requirements on the power supply– on page 162. Small deviations of the electrical mains from the requirements can lead to malfunc- tions of the device. In case the mains deviates strongly from the requirements, the device ®...
  • Page 66 Requirements to the electrical mains ® n Connection to single phase grounded mains, is not valid for b maXX power mod- ules (BM442X for IT systems, BM443X ... BM447X) right wrong Figure 37: Connection to single phase grounded mains (BM443X ... BM447X, without power modules) n Connection to single phase grounded mains with isolated transformer for the follow- ing cases 1) BM441X, BM442X except for IT systems, without power modules...

  • Page 67: Requirements To The Connecting Cables

    Installation Requirements to the connecting cables h You must consider IEC/EN 60204-1, chapter 13 at selection of connection cables. h The protective conductor cross section of the cable must be executed accordant to IEC/EN 60204-1, section 5.2, tab. 1. h The permanent connection of the protective conductor is imperatively regulated for the operation of the device.

  • Page 68: Requirements On The Laying (Emc Notes Device)

    Requirements on the laying (EMC notes device) Requirements on the laying (EMC notes device) NOTE The emission of radio interferences is to a high level dependent on the wiring, the volume ex- pansion and the arrangement of the components in the installation. That is why the assurance of the electromagnetic compatibility according to the statutory provisions only is possible on the completed installation and therefore is in the responsibility range of the manufacturer of the installation or of the operating authority (EMVG §...

  • Page 69: Operating Sequence Of Installation

    Installation NOTE The motor temperature sensor is to be executed in such a way, that the electrical separation is guaranteed. The motor temperature sensors, which are build in at Baumüller correspond to these requirements. At connection of an external motor the operator has to assure, that the motor temperature sensor, which was installed into the motor of the external manufacturer complies with the function Electrical separation.
  • Page 70 6.10 Operating sequence of installation m Connect the encoder (see manual of the encoder modules). NOTE The plugging and pulling of the encoder cable is not permissible under voltage. m Connect the temperature sensor of the motor. m Connect a signal encoder for the pulse enable via terminals X3-5, X3-3.

  • Page 71: Connection Diagrams

    Installation 6.11 Connection diagrams ® 6.11.1 b maXX 44XX (without power modules) Figure 39: Connection diagram with a directly controlled motor brake - without power modules ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 72 6.11 Connection diagrams NOTE If the motor brake is connected directly via X101-2 and X101-3 (see ZFigure 39– on page 71) the shown direct installation is allowed only. It is not allowed within a multi-axis installation e.g. to connect the plus and ground connections of all motor brakes with each other. An additional relay is necessary, if the voltage of the brake is ≠24V, or if the current of the brake is greater than the switching capacity of X101 (see ZX101 (SELV/PELV)–...
  • Page 73 Installation Figure 40: Connection diagram with motor brake controlled via an additional relay - without power modules ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 74: B Maxx ® 44Xx Power Modules

    6.11 Connection diagrams ® 6.11.2 b maXX 44XX power modules Figure 41: Connection diagram with a directly controlled motor brake - power modules ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...
  • Page 75 Installation NOTE If the motor brake is connected directly via X101-2 and X101-3 (see ZFigure 39– on page 71) the shown direct installation is allowed only. It is not allowed within a multi-axis installation e.g. to connect the plus and ground connections of all motor brakes with each other. An additional relay is necessary, if the voltage of the brake is ≠24V, or if the current of the brake is greater than the switching capacity of X101 (see ZX101 (SELV/PELV)–...
  • Page 76 6.11 Connection diagrams Figure 42: Connection diagram with motor brake controlled via an additional relay - power modules ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...
  • Page 77 Installation is only valid for BM444X, BM445X and BM446X accordingly the cooling versions S and A, for BM447X cooling version -A: Figure 43: Connection fan BM447X-A The power supply at X100 or X101 must externally be protected. At selection of the fuse you must consider the cross-section of the connecting cable and the maximum allowable load capac- ity (for X100: see X100 on ZPage...

  • Page 78: Connection Diagrams

    6.12 Connection diagrams A:X1 Encoder module, see manual 5,01042 (SELV/PELV) Encoder Brake PE..1W2 Connections for motor, see ZFigure 44– on page 79 6.12 Connection diagrams ZFigure 44– on page 79 and the following show the connections for protective conduc- tors, mains, motor, chopper resistor, DC-link, safety relays and motor temperature sensor (X101).
  • Page 79 Installation The electrical connections for devices BM4412 and BM4413 are shown in the following figure: Figure 44: Electrical connections for mains, motor, upon others for BM4412 and BM4413 ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 80 6.12 Connection diagrams The electrical connections for device BM4414 are shown in the following figure: Figure 45: Electrical connections for mains, motor, upon others for BM4414 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...
  • Page 81 Installation The electrical connections for device BM442X are shown in the following figure: *) Do not apply terminals when using a power module! Figure 46: Electrical connections for mains, motor, upon others for BM442X ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 82 6.12 Connection diagrams The electrical connections for device BM443X are shown in the following figure: *) Do not apply terminals when using a power module! Figure 47: Electrical connections for mains, motor, upon others for BM443X ® Manual b maXX BM4400 Document No.
  • Page 83 Installation The electrical connections for device BM444X are shown in the following figure: *) Do not apply terminals when using a power module! **) only BM444X-S/-A Figure 48: Electrical connections for mains, motor, upon others for BM444X ® Manual b maXX BM4400 Document No.
  • Page 84 6.12 Connection diagrams The electrical connections for the devices BM445X and BM446X are shown here: *) Do not apply terminals when using a power module! **) only BM445X-S/-A and BM446X-S/-A Figure 49: Electrical connections for mains, motor, upon others for BM445X and BM446X NOTE The chopper resistor is connected at the devices BM445X and BM446X between Ba- and 1C1.
  • Page 85 Installation The electrical connections for device BM447X are shown in the following figure: *) only BM447X-A Figure 50: Electrical connections for mains, motor, upon others for BM447X ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 86 6.12 Connection diagrams NOTE The chopper resistor is connected at the devices BM447X and BM1X between Ba- and 1C1. Also see ZFigure 39– on page 71. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity.
  • Page 87 Installation X100-1: +24V (SELV/PELV) X100-2: +24V (SELV/PELV) X100-3: Mains on (bus) (SELV/PELV) X100-4: Chopper on (SELV/PELV) X100-5: M24V (SELV/PELV) X100-6: M24V (SELV/PELV) UH1: green: Programmable LED yellow: Programmable LED UH2: green: Programmable LED yellow: Programmable LED H1: green: Torque direction1 yellow: Torque direction2 H2: green: Enable yellow: Power ON...
  • Page 88 6.12 Connection diagrams X1: According to controller type BM44XX - XXX - XX0XX[Ryy] - XX (with RS 485 interface) BM44XX - XXX - XX1XX[Ryy] - XX (with RS 485 interface) BM44XX - XXX - XX2XX[Ryy] - XX (with RS 485 interface) 1: reserved 2: TxD RS232 3: RxD RS232...

  • Page 89: Connection Data Of The Connections

    Installation 6.12.1 Connection data of the connections Mains Max. connection Connection tech- Torque Load capac- 1U1, 1V1, 1W1, PE cross-section nology BM441X 2,5 mm plug-in contact ZD.20 Fuse BM442X 4,0 mm screw terminals 0.6 Nm protection– BM443X 10 mm screw terminals 1.5 Nm from page BM444X...
  • Page 90 6.12 Connection diagrams DC link Max. connection Connection tech- Torque Load capacity 1C1 and 1D1 cross-section nology 1C1 and 1D1 Chopper resistor Ba+ and Ba- Ba+ and Ba- BM441X 2,5 mm plug-in contact ZD.6 Elec- trical data - BM442X 4,0 mm Screw terminals 0.6 Nm BM441X basic...
  • Page 91 Installation Motor Max. connection Connection tech- Torque Load capacity 1U2, 1V2, 1W2, PE cross-section nology BM441X 2,5 mm plug-in contact is limited by the device BM442X 4,0 mm screw terminals 0.6 Nm Also seeZAp- BM443X 16 mm screw terminals 4.5 Nm pendix D - Technical BM444X...
  • Page 92 6.12 Connection diagrams X1 (RS 232) Recommended Connection tech- Note connection cable nology BM441X LIYCY 6x2x0.14 mm SUB-D, 9-pin Available as cable sets: ZB.1 Interface cable– BM447X on page 153 WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: mechanical effects.
  • Page 93 Installation Figure 52: Interface cable RS 232 X3 (SELV/PELV) Max. connection cross- Connection tech- Load capacity BB-On section nology Voltage level Quickstop BM441X 1.5 mm plug-in contact BB-On;X3-1, X3-2 Pulse enable and X3-6: BM447X max 1.0 A Quickstop X3-4 Pulse enable; X3-5: 0 (Low) 0 V to 5 V 1 (High) 12 V to 28 V X100 (SELV/PELV)

  • Page 94: Requirements For The Screwing

    6.12 Connection diagrams X101 (SELV/PELV) Max. connection cross- Connection tech- Load capacity section nology Brake BM4412 1.5 mm plug-in contact X101-1 to X101-4: BM4413 min. 0.1 A, max. 0.5 A BM442X BM4414 1.5 mm plug-in contact X101-1 to X101-4: BM443X min.

  • Page 95: Operation

    PERATION In this chapter we describe, how the device works during operation and how you handle the device during operation. Safety instructions h Refer to the safety instructions from the chapter ZFundamental safety instructions– from page 11. CAUTION The following may occur, if you disregard these safety notes: m Property damage The danger is: Environmental conditions, that do not refer to the demands.

  • Page 96: Requirements To The Executing Personnel

    Requirements to the executing personnel Requirements to the executing personnel WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity.When operating with this electrical unit, inevitably certain parts of this unit are under dangerous voltage.

  • Page 97: Enable Signals

    Operation 7.3.1 Enable signals These signals must have a signal level of 24 V (DC) and must be connected to the termi- nals X3-4 and X3-5 (ZFigure 51– on page 87). Pulse enable During operation the signal ’pulse enable’ must constantly be created, so that the device supplies power.

  • Page 98: Operating Condition (H1, H2)

    Display elements - LED 7.5.2 Operating condition (H1, H2) Both of the upper LEDs (H1 and H2) indicate, how the device is working at the time. green: the motor rotates, torque direction 1. orange: the motor rotates, torque direction 2. NOTE The LED H1 cannot be taken as rotational direction indicator.

  • Page 99: Error (H4)

    Operation 7.5.4 Error (H4) LED doesn’t light up: the internal monitoring have not found an error. Red, continuously: Error. h Remove the error with help of the operating program WinBASS II. Additional data is available in ZError detection and troubleshooting– from page 101.

  • Page 100: Monitoring

    Monitoring Example: Error 125 and 91 are existing: Start Time Error- output 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.

  • Page 101: Error Detection And Troubleshooting

    RROR DETECTION AND TROUBLE SHOOTING In this chapter the error messages of the device are described: Error- and warning messages, their meanings and how you can react. Safety instructions h Refer to ZFundamental safety instructions– from page 11. Requirements to the executing personnel ®...

  • Page 102: Monitoring Functions

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

  • Page 103: Error Detection And Troubleshooting

    Error detection and troubleshooting Monitoring function Warning/error Position controller Position deviation dynamic SH P1054 P1050 Position deviation static SH P1055 P1050 Digital output Short-circuit digital output Controller synchroniz- Controller not synchronous with ext. Sig- P0533 P0299 Encoder 1 Cable break Cable break (sin + cos Overspeed...

  • Page 104: Monitoring Functions - Explanations

    Monitoring functions 8.3.1 Monitoring functions - explanations Mains volt- - nonexistent at power modules This monitoring function checks, if the mains voltage has a value within the adjusted voltage range. If the value is lower, the warning ’undervoltage mains’ is indicated. If the value is higher the warning ’overvoltage mains’...

  • Page 105: Error Detection

    Error detection and troubleshooting if there is a short-circuit at the sensor, the error ’short-circuit temperature sensor’ is signaled. The KTY84-sensor has a maximum measuring value of 250 °C. In case this temperature is ex- ceeded, or in case the sensor is not connected, the error ’temperature sensor not connected’ is signaled from the controller.
  • Page 106 Error detection In case the software version of the controller and the WinBASS II version do not comply with one another, you will receive the following message: A further working in this condition is not possible, break up your work and contact Baumüller Nürnberg GmbH in order to receive the right version.
  • Page 107 Error detection and troubleshooting The error message signaled with ’error’ is in WinBASS II: h Open a list in the project tree by clicking on the in front of ’Management’. Figure 53: Project tree in WinBASS II ® Manual b maXX BM4400 Document No.
  • Page 108 Error detection h Select from this list ’Device management’. In the ZFigure 54– on page 108 there is the window ’Device manager’ with a few exemplary (error-) messages. The messages in this window demonstrate an internal list, before the com- munication between controller and pc/laptop with WinBASS II begins, which is arranged accord- ing to the error numbers.

  • Page 109: Structure Of The Error List - Survey Of The Error Parameter Names

    Error detection and troubleshooting 8.4.1 Structure of the error list - survey of the error parameter names Figure 55: Structure of the error list - survey Troubleshooting ® The error messages are based on the troubleshooting in the b maXX devices, which also are termed as error lists (seeZError parameters - error messages (error list) - error reactions–...

  • Page 110: Reset Errors

    Troubleshooting 8.5.1 Reset errors If the red error LED is lighting up, there is at least one error. You can react upon this, by ’reset- ting’ the error in WinBASS II, that means, that you inform the device, that you have noted the error, that you have removed it or that you want to pass over it.

  • Page 111: Error Parameters - Error Messages (Error List) - Error Reactions

    Error detection and troubleshooting 8.5.2 Error parameters - error messages (error list) - error reactions In the following you will find all error messages. An (error) message is shown in WinBASS II in the window ’device manager’. In the list field „Messages“ you find the (abbreviated) error name, ®...
  • Page 112 Troubleshooting Error processor P0201 Error no. Meaning Reaction Troubleshooting reserved ® Watchdog-Error Execute a restart of b maXX 4400 ® Incorrect or unexpected interrupt has Execute a restart of b maXX 4400 occurred ® NMI interrupt/bus error Execute a restart of b maXX 4400 4 to 15 reserved...
  • Page 113 Error detection and troubleshooting Error Proprog communication P203 Error no. Meaning Reaction Troubleshooting ® Timeout protocol Adjustable Execute a restart of b maXX 4400 ® Protocol structure Adjustable Execute a restart of b maXX 4400 Wrong module type Adjustable Contact Baumüller too many data in the telegram Adjustable Contact Baumüller Not enough data in telegram...
  • Page 114 Troubleshooting Error in function or option modules P0204 Error no. Meaning Reaction Troubleshooting Error in Level 3 ZError function module A to E P0240 to Function module A error P0244– on page 129 (= 3. level) Error in Level 3 ZError function module A to E P0240 to Function module B error...
  • Page 115 Error detection and troubleshooting Error power supply P0205 Error no. Meaning Reaction Troubleshooting Mains failure Adjustable Restore the connection to the power supply Phase failure Check if all phases are correctly connected and voltage-carrying Mains undervoltage Assure the compliance with the mains specifi- cations (see techn.
  • Page 116 Troubleshooting Error no. Meaning Reaction Troubleshooting Mains failure Restore the mains supply Mains undervoltage Assure the compliance with the mains specifi- cation (see technical data) Mains overvoltage Assure the compliance with the mains specifi- cation (see technical data) Undervoltage U Check the power connections DC link reserved...
  • Page 117 Error detection and troubleshooting Error Encoder1 P0208 Error no. Meaning Reaction Troubleshooting ®) Communication error see encoder 1 (Hiperface P0234 ® (Hiperface -Specification) (= 3rd level) reserved Error at overwriting of Execute the command again.If the error occurs Encoder position information again, contact Baumüller Nürnberg GmbH.
  • Page 118 Troubleshooting Error encoder 2 P0209 Error no. Meaning Reaction Troubleshooting Communication error (hiper- See encoder 2 (hiperface) P0235 (= 3rd level) face specification) Module code invalid Use a different encoder reserved Cable break encoder 2 Remove the cable break in encoder encoder cable of encoder 2, check assignment of encoder cable Overspeed encoder 2...
  • Page 119 Error detection and troubleshooting Error encoder manager P0210 Error no. Meaning Reaction Troubleshooting Absolute position of encoder 1 Use another encoder unknown Absolute position of encoder 2 Use another encoder unknown Encoder module 1 is missing Check, if the right encoder is connected to module position A Encoder module 2 is missing Check, if the right encoder is connected to...
  • Page 120 Troubleshooting Error device manager P0211 Error no. Meaning Reaction Troubleshooting Timeout communication Adjustable Remove the timeout of the Proprog communication Timeout BACI Adjustable Remove the timeout of the BACI communica- tion option module Timeout cyclic communication Adjustable Remove the timeout of the Cyclic communication: Timeout required data Adjustable Remove the timeout of the required data com-...
  • Page 121 Error detection and troubleshooting Error data record manager P0212 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 records Checksum error EEPROM EEPROM faulty or described faulty No boot data set...
  • Page 122 Troubleshooting Error position controller P0213 Error no. Meaning Reaction Troubleshooting Position deviation dynamic Adjustable Remove the dynamical position deviation error Position deviation static Adjustable Remove the statical position deviation error Encoder 1 is used for position control, activate encoder 1 but is inactive.
  • Page 123 Error detection and troubleshooting Error speed controller P0214 Error no. Meaning Reaction Troubleshooting Drive blocked Remove the blockade of the drive Encoder 1 is parameterized as encoder You have got to either activate the encoder in for the motor control, but the evaluation the encoder 1 (modeP0150) or you set the is not activated.
  • Page 124 Troubleshooting 3. Level Error power unit - serial interface P0233 (communication error to the power unit) Error code Meaning Troubleshooting Data overflow Error indicates high EMC problems; please reduce these. Contact Baumüller Bit frame error Error indicates high EMC problems; please reduce these.
  • Page 125 Error detection and troubleshooting Error code Meaning Troubleshooting Wrong data checksum Error indicates high EMC problems; please reduce these. Contact Baumüller No response Error indicates high EMC problems; please reduce these. Contact Baumüller ® Invalid response Restart of b maXX ®...
  • Page 126 Troubleshooting Error encoder 1 - serial interface P0234 Error encoder 2 - serial interface P0235 (communication error after Hiperface specification in the encoder 1 /encoder 2) Error code Meaning Troubleshooting Analog signals outside specification Check the encoder cable and if the encoder has been connected correctly.
  • Page 127 Error detection and troubleshooting Error code Meaning Troubleshooting 19 to 27 reserved Absolute monitoring of the analog signals Check the encoder cable and if the encoder has been connected correctly. Transmission current critical Check the encoder cable and if the encoder has been connected correctly.
  • Page 128 Troubleshooting Error code Meaning Troubleshooting Invalid command Check the encoder cable and if the encoder has been connected correctly. Error in response telegram Check the encoder cable and if the encoder has been connected correctly. Alarm bit is set Restart the system Memory is occupied Check the encoder cable and if the encoder has been connected correctly.
  • Page 129 Error detection and troubleshooting Error finding notch position P0237 Error code Meaning Troubleshooting Overcurrent step 1 Method 2: Increase maximum current P1241, decrease voltage amplitude P2122 Overcurrent step 2 Method 2: Increase maximum current P1241, decrease voltage amplitude P2122 Plausibility step 1 Method 0: Check direction of rotation P0087, current is too low or shaft is not free enough to move...
  • Page 130 Troubleshooting Error option module G to M P0245 to P0250 Error code Meaning Reaction Troubleshooting 4096 Wrong parameter no. at setpoint Adjustable Check the according setpoint parameter parameter 1 4097 Wrong parameter no. at setpoint Adjustable Check the according setpoint parameter parameter 2 4098 Wrong parameter no.
  • Page 131 Error detection and troubleshooting Error code Meaning Reaction Troubleshooting 4114 Wrong parameter no. at actual value Adjustable Check the according actual value parameter parameter 3 4115 Wrong parameter no. at actual value Adjustable Check the according actual value parameter parameter 4 4116 Wrong parameter no.
  • Page 132 Troubleshooting Error code Meaning Reaction Troubleshooting 4133 Invalid value at Adjustable Make sure that you have got correct values setpoint parameter no. 6 within the permitted value range. 4134 Invalid value at Adjustable Make sure that you have got correct values setpoint parameter no.
  • Page 133 Error detection and troubleshooting Error code Meaning Reaction Troubleshooting 4153 Internal error: Wrong BACI status Adjustable Contact Baumüller 4154 Access conflicts with slave at cyclic Adjustable Contact Baumüller Communication: 4155 Error cyclic Communication: Parameter Adjustable Contact Baumüller value wrong 4156 Error cyclic Communication: Alive- Adjustable Check the value of the transmitted parameter counter conflict...

  • Page 134: Parameter Description - Warnings (Warning Bit List)

    Troubleshooting Error code Meaning Reaction Troubleshooting 4174 Configuration cyclic services: Parame- Adjustable Select another parameter ters are not cyclic writeable 4175 Configuration cyclic services: Invalid Adjustable Select another parameter parameter number 4176 Wrong option module error code Adjustable Contact Baumüller 4177 to 8191 reserved 8192 Error CANopen timeout on CAN bus...
  • Page 135 Error detection and troubleshooting Warnings power unit P0262 Warning no. Meaning Troubleshooting Inside temperature of device Establish the specified environmental conditions, assure correct ventilation conditions Heat sink temperature Reduce the power output, check the fans of the device Timeout charge process DC link Check the correct order of mains phases (clockwise rotating field!) and avoid that the DC link supplies energy while charging.
  • Page 136 Troubleshooting ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 137: Maintenance

    AINTENANCE In this chapter we describe, how you can safely maintain your device. Safety instructions h Refer to ZFundamental safety instructions– from page 11. h Refer to the danger areas of the devices. Figure 56: Danger areas BM441X, BM442X, BM443X and BM444X ®...

  • Page 138: Environmental Conditions

    Environmental conditions Figure 57: Danger areas BM445X, BM446X and BM447X Environmental conditions If the prescribed environmental conditions are complied with, the device is maintenance- free. The prescribed environmental conditions are to be found in chapter ZAppendix D - Technical data– from page 161.

  • Page 139: Inspection Intervals - Maintenance Notes

    Maintenance Inspection intervals - maintenance notes Baumüller Nürnberg GmbH recommends a steady checking of the environmental condi- tions. Thus you will receive the possibility, to react immediately, in case the actual condi- tions deviate from the prescribed conditions. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity.
  • Page 140 Inspection intervals - maintenance notes ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 141: Repair

    EPAIR In this chapter we describe, where the devices are repaired. WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. After a faulty repair the device doesn’t fulfill the safety instructions anymore.
  • Page 142 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 143: Shutdown, Storage

    HUTDOWN STORAGE In this chapter we describe, how you decommission and store the device. 11.1 Safety instructions h Refer to ZFundamental safety instructions– from page 11 and the information in ZTransportation and packing– from page 25. The shutdown of the device may only be carried out by for this qualified personnel. DANGER The following will occur, if you disregard this safety note: m serious personal injury m death...

  • Page 144: Requirements To The Executing Personnel

    11.2 Requirements to the executing personnel 11.2 Requirements to the executing personnel The personnel, who is appointed to setting out of operation, must have the required knowledge and instructions, which is necessary for an execution according to the rules. Select the personnel in such a way, that the safety instructions, which are mounted to the device and its parts as well as to the connections, are understood and applied to.

  • Page 145: Storage Conditions

    Shutdown, storage 11.5 Storage conditions The device is maintenance-free. If you keep to the environmental conditions during the entire period of storage, you can assume, that the device will not be damaged. In case the environmental conditions during storage are not kept, you should assume that the de- vice is damaged after storage.
  • Page 146 11.6 Recommissioning ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 147: Disposal

    ISPOSAL In this chapter we describe the correct and safe disposal of the devices of the series ® b maXX . During the disposal you will mainly get metal parts (iron- and non-iron metal), electronic scrap and plastics. NOTE Baumüller products do not belong to the scope of the EU guideline for the disposal of electri- cal and electronics devices (WEEE, 2002/96/EG).
  • Page 148 12.1 Safety instructions CAUTION The following may occur, if you disregard these safety notes: m minor to medium personal injury. The danger is: sharp edges. The components of the device, sheet metal components, heat sinks and so on can have sharp edges! In case you lift a device during demounting with non-protected hands, your fingers/palms can be cut.

  • Page 149: Requirements To The Executing Personnel

    Disposal 12.2 Requirements to the executing personnel The personnel, whom you instruct to dispose/demount the device must have the knowl- edge and training to execute these works properly. The personnel is to be selected in such a way, that the safety instructions on the device and its parts is understood and re- ferred to by the personnel.

  • Page 150: Recycling Plants/Offices

    12.4 Recycling plants/offices CAUTION The following can occur, if you disregard this warning instruction: m Environmental pollution The danger is: incorrect disposal. Capacitors, semiconductor modules and electronic scrap is to be recycled as special waste. Capacitors (E) Capacitors are to be recycled as special waste. Thereby refer to the relevant instruc- tions.

  • Page 151: Appendix A - Abbreviations

    A - A PPENDIX BBREVIATIONS Ampere EXT, ext external Alternating current Residual current Function module analog input/out- Function module fast digital input output ASCII American Standard Code for Infor- Synchronous operation mation Interchange Ramp function generator BACI Baumüller drives communication Main contactor interface Main contactor on...
  • Page 152 Actual value channel Association for Electrical, Elec- troninc & Information Technolo- Power unit gies Reference potential 24 V Logic element Torque direction 1 DC-link Torque direction 2 n = 0 Speed = 0 Speed actual value Maximum speed Minimum speed Altitude over sea level Speed setpoint value soll...

  • Page 153: Appendixb - Spare Parts And Accessories

    B - S PPENDIX PARE PARTS AND ACCESSORIES In this appendix we are listing the spare-/accessory parts for the devices of the series ® b maXX . In case you have questions and suggestions according the accessories, do not hesitate to contact our product management. Interface cable NOTE Screening of the interface cables, which are used may only be connected to the controller side...

  • Page 154: Dust Cover And Connector

    Dust cover and connector Dust cover and connector Dust cover (yellow) narrow 351209 Dust cover (yellow) wide 351210 Connector ’Motor’ 354746 Phoenix: GIC 2.5/4-ST-7.62, 1828825 Connector „1C1/1D1“ or „1C1/1D1/Ba“ 354746 Phoenix: GIC 2.5/4-ST-7.62, 1828825 Connector ’1C1/1D1/Ba’ 381872 Phoenix: GIC 2.5/2-ST-7.62 Connector ’mains’...

  • Page 155: Declaration Of Conformity/ By Manufacturer, Ul - Certification

    PPENDIX ECLARATION OF ONFORMITY , UL - C ANUFACTURER ERTIFICATION In this section we provide general information about EU directives, the CE symbol and the Declaration of Conformity/by Manufacturer. What is an EU directive? EU directives specify requirements. The directives are written by the relevant bodies with- in the EU and are implemented by all the member countries of the EU in national law.

  • Page 156: Definition Of The Term Declaration Of Conformity

    Definition of the term Declaration of Conformity With specified application of this Baumüller equipment in your machinery, you can act on the assumption that the equipment satisfies the requirements of 98/37/EG (machinery di- rective). Therefore the equipment is developed and constructed in such a way, that the requirements of the harmonized standard EN 60204-1 can be met by the electrical instal- lation.

  • Page 157: Declaration Of Conformity

    Declaration of Conformity/ by Manufacturer, UL - Certification Declaration of Conformity ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 158: Declaration By Manufacturer

    Declaration by Manufacturer Declaration by Manufacturer ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 159: Ul-Certification

    Declaration of Conformity/ by Manufacturer, UL - Certification UL-certification UL is a mark of conformity, which is assigned from Underwriters Laboratories Inc. (www.ul.com), an American company. The UL-certification is not statutory regulated, but takes place voluntarily. In order to be allowed to mark equipments and components with the UL-mark of confomity, tests must have to be done, which are attended and documentated by an UL-inspector.
  • Page 160 UL-certification ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 161: Appendixd - Technical Data

    D - T PPENDIX ECHNICAL DATA ® In this chapter you find the detailed technical data for all sizes of the device series b maXX BM4400. ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...

  • Page 162: Requirements On The Power Supply

    Requirements on the power supply Requirements on the power supply Mains BM44XX - XTX Industrial system with direct or low impedance grounded star point (TN-mains or TT-mains) BM44XX - XIX Industrial supply network with a grounded star point (IT-system), which has no or high impedance Industrial system with direct or low impedance earthed junction of phases (grounded delta wye)

  • Page 163: Technical Data

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

  • Page 164: Required Environmental Conditions

    Required environmental conditions Required environmental conditions Transportation temperature range - 30 °C bis + 70 °C Transportation climatic category 2 K 3 Storage temperature range - 30 °C bis + 70 °C Storage climatic class 1 K 4 Operation electrical environment Industrial supply network Operation temperature range min.

  • Page 165: Cooling

    Technical data EN 50178, chapter 9.4.3.2 EN 50178, table 2 NOTE Normally only a non-conductive pollution occurs. Any conductive pollution (for a short period or continuous) is not permitted and can lead to the destruction of the device. The customer is responsible for destructions based on pollution with conductive substance or materials.

  • Page 166: Non-Electrical Data

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

  • Page 167: Electrical Data - Bm441X Basic Unit

    Technical data Electrical data - BM441X basic unit BM4412 BM4413 Input rated power 1.9 kVA 3.3 kVA Input rated current 2.8 A 4.8 A Distortion factor of the input current (THD 119% 110% Input current max. (I 5.2 A 9.0 A DC-link rated voltage 540 V 110 µF...
  • Page 168 Electrical data - BM441X basic unit 8)9) BM4414-STx BM4414-CTx Input rated power 5.1 kVA 6.9 kVA Input rated current 7.3 A 10.0 A Distortion factor of the input current (THD 109% 113% Input current max. (I 20.0 A 20.0 A DC-link rated voltage 540 V 330 µF...
  • Page 169 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Derating of the output current...
  • Page 170 Electrical data - BM441X basic unit The specified value is only valid, if there is no additional DC link capacity connected to the DC link terminals. Also see ZMains-switch- on frequency/DC-link charging– on page 97 and ZFigure 61– on page 170. 5000 4500 4000...

  • Page 171: Electrical Data - Bm442X Basic Unit

    Technical data Electrical data - BM442X basic unit BM4422 BM4423 BM4424 Input rated power 5.6 kVA 8.6 kVA 11.8 kVA Input rated current 8.1 A 12.4 A 17.0 A Distortion factor of the input current (THD 107 % 109 % 109 % Input current, max.
  • Page 172 Electrical data - BM442X basic unit BM4425 BM4426 Input rated power 11.8 kVA 13.2 kVA Input rated current 17.0 A 19,0 A Distortion factor of the input current (THD 109% Input current, max. (I 34.0 A 37.0 A DC-link rated voltage 540 V 705 µF 705 µF...
  • Page 173 Technical data Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Derating of the output current Mains voltage [V] Figure 62: Derating of the output current BM 442X basic unit Between 40°...
  • Page 174 Electrical data - BM442X basic unit The specified value is only valid, if there is no additional DC link capacity connected to the DC link terminals. Also see ZMains-switch- on frequency/DC-link charging– on page 97 and ZFigure 63– on page 174. The sum of the transferred average effective power via the DC link terminals and the transferred average effective power via the motor terminals must not exceed the specified value permanently.

  • Page 175: Electrical Data - Bm443X Basic Unit

    Technical data Electrical data - BM443X basic unit BM4432 BM4433 1)2) Input rated power 13.3 kVA 16.8 kVA 1)2) Input rated current 19.2 A 24.2 A 1)2) Distortion factor of the input current (THD Input current, max. 37.0 A 45.0 A DC-link rated voltage 540 V 820 µF...
  • Page 176 Electrical data - BM443X basic unit BM4434 BM4435 1)2) Input rated power 26.3 kVA 36.7 kVA 1)2) Input rated current 38.0 A 53.0 A 1)2) Distortion factor of the input current (THD Input current, max. 71.0 A 71.0 A DC-link rated voltage 540 V 1640 µF 2000 µF...
  • Page 177 Technical data Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Figure 64: Derating of the output current BM 443X basic unit Between 40°...

  • Page 178: Electrical Data - Bm444X Basic Unit

    Electrical data - BM444X basic unit Electrical data - BM444X basic unit BM4443 BM4444 BM4445 BM4446 (preliminary) 1)2) Input rated power 49 kVA 58 kVA 73 kVA 94 kVA 1)2) Input rated current 70,0 A 84 A 105 A 136 A 1)2) Distortion factor of the input current (THD...
  • Page 179 Technical data All rated values refer to a mains input voltage of 400 V/50 Hz and a control voltage of 24 V. In case you use the following commutation chokes at a mains with u =0.4%: K,mains BM4443 Part no. 00368380, BM4444: Part no. 00368381, BM4445: Part no. 00368381. The output voltage is a pulsed d.c.

  • Page 180: Electrical Data - Bm445X Basic Unit

    D.10 Electrical data - BM445X basic unit D.10 Electrical data - BM445X basic unit BM4452 BM4453 BM4454 1)2) Input rated power 75.5 kVA 94.2 kVA 138.6 kVA 1)2) Input rated current 109 A 136 A 200 A 1)2) Distortion factor of the input current (THD Input current, max.
  • Page 181 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Derating of the output current...

  • Page 182: Electrical Data - Bm446X Basic Unit

    D.11 Electrical data - BM446X basic unit D.11 Electrical data - BM446X basic unit BM4462 BM4463 BM4466 (preliminary) 1)2) Input rated power 164 kVA 204 kVA 238 kVA 1)2) Input rated current 237 A 295 A 344 A 1)2) Distortion factor of the input current (THD Input current max.
  • Page 183 Technical data RMS at an environmental temperature of 40 °C. At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current Mains voltage [V]...

  • Page 184: Electrical Data - Bm447X Basic Unit

    D.12 Electrical data - BM447X basic unit D.12 Electrical data - BM447X basic unit BM4472 - A/FIX BM4473 - A/FIX 1)2) Input rated power 328 kVA 412 kVA 1)2) Input rated current 474 A 594 A 1)2) Distortion factor of the input current (THD Input current max.

  • Page 185: Bm447X, Additional Information To Emc

    Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of the output current Derating of the output current Mains voltage [V] Mains voltage [V] Figure 68:...

  • Page 186: Electrical Data - Bm442X Power Module

    D.13 Electrical data - BM442X power module D.13 Electrical data - BM442X power module BM4422- BM4423 - BM4424 - BM4425 - XXX - XXX - XXX - XXX - 2XXXX 2XXXX 2XXXX 2XXXX Input rated power 4,3 kW 6,2 kW 8,2 kW 8,2 kW Input rated current...
  • Page 187 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating output current Derating output current DC link voltage [V] DC link voltage [V] Derating output current...

  • Page 188: Electrical Data - Bm443X Power Module

    D.14 Electrical data - BM443X power module D.14 Electrical data - BM443X power module BM4432- BM4433 - BM4434 - BM4435 - XXX - XXX - XXX - XXX - 2XXXX 2XXXX 2XXXX 2XXXX Input rated power 12,0 kW 15,3 kW 23,3 kW 32,3 kW Input rated current...
  • Page 189 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current Derating of output current DC link voltage [V] DC link voltage [V] Derating of output current...

  • Page 190: Electrical Data - Bm444X Power Module

    D.15 Electrical data - BM444X power module D.15 Electrical data - BM444X power module BM4443- BM4444- BM4445 - BM4446 - XXX - XXX - XXX - XXX - 2XXXX 2XXXX 2XXXX 2XXXX (Preliminary) Input rated power 41 kW 50 kW 64 kW 84 kW Input rated current...
  • Page 191 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current Derating of output current DC link voltage [V] DC link voltage [V] Derating of output current...

  • Page 192: Electrical Data - Bm445X Power Module

    D.16 Electrical data - BM445X power module D.16 Electrical data - BM445X power module BM4453- XXX - 2XXXX Input rated power 85 kW Input rated current 158 A Input current, max. (I 206 A DC link rated voltage 540 V DC link capacity (internal) 3000 µF DC link discharging time...
  • Page 193 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current DC link voltage [V] Figure 72: Derating of output current BM 445X power modules The output current must be reduced between 40°...

  • Page 194: Electrical Data - Bm446X Power Module

    D.17 Electrical data - BM446X power module D.17 Electrical data - BM446X power module BM4462- XXX - 2XXXX BM4463- XXX - 2XXXX Input rated power 150 kW 180 kW Input rated current 278 A 335 A Input current, max. (I 392 A 436 A DC link rated voltage...
  • Page 195 Technical data At rated input supply voltage the device enables the rated-/maximum output currents. At input voltages above the rated supply voltage the output currents at constant output power have to accordingly be reduced. Derating of output current Derating of output current DC link voltage [V] DC link voltage [V] Figure 73:...

  • Page 196: Additional Data Bm44Xx With Water-Cooled Chopper Resistors

    D.18 Additional data BM44XX with water-cooled chopper resistors D.18 Additional data BM44XX with water-cooled chopper resistors Technical data of water-cooled chopper resistors: Type of device Chopper Chopper Peak Continuous Depth of resistor resistor power output device current BM4434-ZIX/FIX-XXXXXR16 Ω 49 A 38 kW 2 kW + 20 mm...

  • Page 197: Output-Frequency-Dependent Current-Derating

    Technical data D.19 Output-frequency-dependent current-derating All Baumüller devices were developed in such a way, that the specified output-measuring cur- rents are continuously, i. e. in the S1 operation, that they are permissible from an electric output frequency of more than 15 Hz. If the static converter output frequency is less than 15 Hz and if the frequency lasts longer than 5 seconds between 0 and 15 Hz, the continuously permissible output current must be reduced according to the following characteristic curve.

  • Page 198: Fuse Protection

    D.20 Fuse protection D.20 Fuse protection We differ between the protection of the supply cables and the protection of the device. In order to fulfill the CE specifications - here especially EN60204-1 - you have to protect the supply ca- bles.

  • Page 199: Cable Protection

    Technical data D.20.1 Cable protection The current-carrying capacity of conductors is determined in table 5 of EN60204-1. For your op- eration you must determine the accordant value in the standard yourself, by taking into consid- eration, amongst other things the cable mounting. Here you will find an extraction for the laying of PVC- isolated cables on open cable racks: Cable cross sec- Fuse-...

  • Page 200: Cable Protection + Device Protection

    D.20 Fuse protection D.20.3 Cable protection + device protection Consider by your choice of the whole range fuses the current-carrying capacity of the, to the de- vice connected mains cables and the allowable maximum load of the device. D.20.4 Whole range fuses gR (device and cable) BM4412X, BM4413, model NH Bussmann 000 16A/690V: 170M1559 u 20A/690V: 170M1560 u...

  • Page 201: Whole Range Fuses Gr (Device And Cable) Bm4414, Model Nh

    Technical data D.20.6 Whole range fuses gR (device and cable) BM4414, model NH Bussmann 000 25A/690V: 170M1561 32A/690V: 170M1562 Ferraz Shawmut 000 16A/690V: 6.9 GGR 000 PV 016 20A/690V: 6.9 GGR 000 PV 020 00 16A/690V: 6.9 GGR 00 PV 016 SIBA 000 16A/690V: 2047734/16A 20A/690V: 2047734/20A...

  • Page 202: Whole Range Fuses Gr (Device And Cable) Bm4422X, Model Nh

    D.20 Fuse protection D.20.8 Whole range fuses gR (device and cable) BM4422X, model NH Bussmann 000 16A/660V: 170M1559 u 20A/660V: 170M1560 u 25A/660V: 170M1561 u 32A/660V: 170M1562 u 00 16A/690V: 170 m 20A/690V: 170 m 25A/690V: 170 m 32A/690V: 170 m SIBA 000 16A/690V: 2047734/16A U 00 20A/690V: 2047720/20A...

  • Page 203: Whole Range Fuses Gr (Device And Cable) Bm4423X, Model Nh

    Technical data D.20.10 Whole range fuses gR (device and cable) BM4423X, model NH Bussmann 000 20A/660V: 170M1560 u 25A/660V: 170M1561 u 32A/660V: 170M1562 u 00 20A/690V: 170M2693 25A/690V: 170M2694 32A/690V: 170M2695 Ferraz Shawmut 000 20A/690V: 6.9 GGR 000 PV 020 00 20A/690V: 6.9 GGR 00 PV 020 SIBA 000 20A/690V: 2047734/20A U...

  • Page 204: Whole Range Fuses Gr (Device And Cable) Bm4424, Bm4425 And Bm4426, Model Nh

    D.20 Fuse protection D.20.12 Whole range fuses gR (device and cable) BM4424, BM4425 and BM4426, model NH Bussmann 000 25A/660V: 170M1561 u 32A/660V: 170M1562 u 00 25A/690V: 170M2694 32A/690V: 170M2695 Ferraz Shawmut 000 25A/690V: 6.9 GGR 000 PV 025 00 25A/690V: 6.9 GGR 00 PV 025 SIBA 000 25A/690V: 2047734/25A U 00 25A/690V:...

  • Page 205: Whole Range Fuses Gr (Device And Cable) Bm443X Model Nh

    Technical data D.20.14 Whole range fuses gR (device and cable) BM443X model NH Bussmann 000 50A/660V: 170M1564 u 63A/660V: 170M1565 u 00 50A/690V: 170M2697 63A/690V: 170M2698 1 50A/690V: 170M4176 63A/690V: 170M4177 SIBA 00 63A/690V: 2047720/63A 1 63A/690V: 2021120/63A Siemens 00 63A/660V: 3NE8 018-1 U 0 50A/1000V: 3NE4 117 Size D.20.15 Semiconductors aR (device) BM443X, model NH...

  • Page 206: Full-Range Fuses Gr, Grl, Gr/Gs, Ggr (Device And Cable) Bm444X, Model Nh

    D.20 Fuse protection D.20.16 Full-range fuses gR, gRL, gR/gS, gGR (device and cable) BM444X, model NH Bussmann 00 80A/690V: 170M2699 100A/690V: 170M2700 125A/690V: 170M2701 1 80A/690V: 170M4178 100A/690V: 170M4179 125A/690V: 170M4180 160A/690V: 170M4181 Ferraz Shaw- 000 80A/690V: 6.9 GGR 000 PV 080/ 6,9 GGR 000 D08L 080 00 80A/690V: 6.9 GGR 00 PV 080/ 6,9 GGR 00 D08L 080...

  • Page 207: Semiconductors Ar (Device) Bm444X, Model Nh

    Technical data D.20.17 Semiconductors aR (device) BM444X, model NH Bussmann 000 80A/690V: 170M1566 U 100A/690V: 170M1567 U 125A/690V: 170M1568 U 160A/690V: 170M1569 U 00 80A/1000V: 170M2680 100A/1000V: 170M2681 125A/1000V: 170M2682 1 80A/690V: 170M3811 U 100A/690V: 170M3812 U 125A/690V: 170M3813 U 160A/690V: 170M3814 U SIBA 1 125A/690V: 2021120/125A...

  • Page 208: Whole Range Fuses Gr (Device And Cable) Bm445X Model Nh

    D.20 Fuse protection D.20.18 Whole range fuses gR (device and cable) BM445X model NH Bussmann 00 100A/690V: 170M2700 125A/690V: 170M2701 160A/690V: 170M2702 1 125A/690V: 170M4180 160A/690V: 170M4181 200A/690V: 170M4182 250A/690V: 170M4183 2 200A/690V: 170M5881 250A/690V: 170M5882 315A/690V: 170M5883 3 350A/690V: 170M6080 Ferraz Shawmut 000 100A/690V: 6.9 GGR 000 PV 100 00 100A/690V: 6.9 GGR 00 PV 100 125A/690V: 6.9 GGR 00 PV 125...

  • Page 209: Semiconductors Ar (Device) Bm445X, Model Nh

    Technical data D.20.19 Semiconductors aR (device) BM445X, model NH Bussmann 000 125A/660V: 170M1568 u 160A/660V: 170M1569 u 200A/660V: 170M1570 u 250A/660V: 170M1571 u 315A/660V: 170M1572 u 00 125A/1000V: 170M2682 160A/1000V: 170M2683 200A/900V: 170M2684 225A/900V: 170M2685 1 160A/660V: 170M3814 200A/660V: 170M3815 250A/660V: 170M3816 315A/660V: 170M3817 350A/660V: 170M3818...

  • Page 210: Whole Range Fuses Gr (Device And Cable) Bm446X Model Nh

    D.20 Fuse protection D.20.20 Whole range fuses gR (device and cable) BM446X model NH Bussmann 1 250A/690V: 170M4183 315A/690V: 170M4184 350A/690V: 170M4185 400A/690V: 170M4186 2 250A/690V: 170M5882 315A/690V: 170M5883 350A/690V: 170M5884 400A/690V: 170M5885 450A/690V: 170M5886 3 350A/690V: 170M6080 400A/690V: 170M6081 450A/690V: 170M6082 SIBA 1 250A/690V: 2021134/250AU...
  • Page 211 Technical data Ferraz Shawmut 000 250A/690V: 6.9 URD 000 PV 0250 315A/690V: 6.9 URD 000 PV 0315 00 250A/690V: 6.9 URD 00 PV 0250 315A/690V: 6.9 URD 00 PV 0315 0 250A/690V: 6.9 URD 0 PV 0250 315A/690V: 6.9 URD 0 PV 0315 1 250A/690V: 6.9 URD 1 PV 0250 315A/690V: 6.9 URD 1 PV 0315 350A/690V: 6.9 URD 1 PV 0350...

  • Page 212: Semiconductor Fuses Ar (Device) 447X, Model Nh

    D.20 Fuse protection D.20.22 Semiconductor fuses aR (device) 447X, model NH WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: electricity. Parts, which are under tension are perilous. The use of semiconductor fuses is obligatory at the mains connection of BM447X devices. Semiconductor fuses are required in the chopper resistor connection except the user assures the short-circuit protection of resistor and cable.

  • Page 213: Cables Mains-Device

    Technical data D.21 Cables mains-device Device Cross section Maximum length Connection to device BM441X 4 x 0.5 to 2,5 mm mains to mains filter: user- flexible cable (AWG 16 - 12) defined with/without wire end ferrule mains filter to mains choke/ (plug-in terminal) device: max.
  • Page 214 D.21 Cables mains-device Connection lugs (current bars).Position see ZFigure 49– on page 84. Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar. Connection lugs (current bars). Position see ZFigure 49–...

  • Page 215: Cables Device-Motor

    Technical data D.22 Cables device-motor 2)3) Device Cross section maximum length Connection to device BM441X 4 x (1 to 2,5 mm dependent on the used cross sec- flexible cable with/without wire (AWG 16 - 12) tion: end ferrule (plug-in terminal) BM442X 4 x (0.2 to 4 mm 4 x 1.5 to 2,5 mm...

  • Page 216: Cable Control Voltage Supply/Signals

    D.23 Cable control voltage supply/signals Connection lugs (current bars). Position see ZFigure 49– on page 84 Screw maximum two cable lugs to the current bar - one on the front side, one on the reverse side of the bar. Connection lugs (current bars). Position see ZFigure 50–...

  • Page 217: Type Of Protection

    Technical data D.24 Type of protection Type of protection BM 441X, BM 442X IP 20 BM 443X, BM 444X IP 20, if safe-to-touch connection according to IP 20, otherwise IP 10 BM 445X, BM 446X, BM 447X IP 00 D.25 Fire fighting appliances Fight fire with ABC-Pulver D.26 Mains filters BM441X to BM447X...

  • Page 218: Mains Chokes

    D.27 Mains chokes IT-mains Type Item number Bem AC 250 A BFN 3-1 - 250 - 002 373620 320 A BFN 3-1 - 320 - 002 373894 400 A BFN 3-1 - 400 - 002 373898 600 A BFN 3-1 - 600 - 002 373902 Rated temperature = 40°...

  • Page 219: Temperature Sensors Of The Motor

    Technical data Inductance Type designation Part No. Part No. rated AC Type -001, Type -002, Connection Connection copper conductor bar terminal 55 µH 530 A BK3-0530/0650 368387 48 µH 615 A BK3-0615/0750 368388 39 µH 750 A BK3-0750/0920 368389 32,6 µH 920 A BK3-0900/1100 368390...
  • Page 220 D.28 Temperature sensors of the motor ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 221: Appendixe - Safe Stop

    E - S PPENDIX AFE STOP In this chapter we describe the safety function „Safe stop“. Methods to avoid an unexpected starting In order to avoid danger for persons, for example operators, service- and maintenance technics, the machine has to be kept in a safe state (safe stop), while taking action in the dangerous area of the machine.

  • Page 222: Methods To Avoid An Unexpected Starting

    Methods to avoid an unexpected starting The power supply to the windings of the motor is reached at a stoppage by inhibiting the power semiconductor. As semiconductors possibly can fail or be started, because of electromagnetic interferences, the behavior of the shut down drive has to be considered if such an error scenario arises.

  • Page 223: Safety Categories According To En

    Safe stop Safety categories according to EN 954-1 Dependent on the possible dangers (these are rated due to the consideration of the severity of the injuries, the frequency of the length of stay within the danger area and possibilities in order to prevent dangers) safety-related components of machines must meet certain safety criteria.

  • Page 224: The Safety Relay

    The safety relay The safety relay The function of the safety relay is executed in fail-safe-technic, also named closed-circuit prin- ciple. The safety function ’Safe stop” is active, as long as no voltage is applied to the input ter- minals (X102-3/4; X103-3/4). Consequently the functioning of the safety function is guaranteed if power failure operates.

  • Page 225: Sequence Diagram

    Safe stop E.3.2 Sequence diagram Figure 76: Sequence diagram for one or two safety relays ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 226 The safety relay Figure 77: Time diagram: Recommended switch on/switch off sequence (4) (1) T dependent of the option module, which is used (from firmware version 03.05) Boot controller about 5 s. (2) T : 1.5 s (exception b maXX443X: 6 s). charge DC (3) T : 20 ms (exception b maXX 442X: 200 ms).
  • Page 227 Safe stop Deviant switch on-/switch off possibilities BM441x to BM446x Switch on- and switch off require- ment Auxiliary supply (24 V) and safety relay 1 + 2 and mains simultaneously ON Auxiliary supply (24 V) and safety relay 1 + 2 simultaneously ON Mains „OFF“...

  • Page 228: Application Example For Machine Of Category 3

    Application example for machine of category 3 Application example for machine of category 3 Exemplary, the following diagram shows the usage and cabling of a Baumüller converter of the series b maXX in a machine tool, at which the safe taking of work pieces at opened cover is possible according to category 3 (EN 954-1).
  • Page 229 Safe stop the monitoring circuit has recognized an error (for example different switch state of S1 and S2), this is displayed to the operator and a commissioning of the drive is not possible until the error has been repaired. n The status signal contact of the safety relay (X102:1; NC contact) can additionally be evalu- ated by the monitoring circuit (not imperative).

  • Page 230: Application Example For Machine Of Category

    Application example for machine of category 4 Application example for machine of category 4 The diagram shows exemplary the usage and cabling of a Baumüller converter of the series b maXX (BM443X-XX2, BM444X-XX2, BM445X-XX2, BM446X-XX2, BM447X-XX2) of a machine tool, at which the safe taking of work pieces at opened cover according to category 4 (EN 954- 1) is possible.
  • Page 231 Safe stop n The monitoring circuit, a fail-safe monitoring control of the category 4 (EN 954-1), checks on its own the directly connected switch contacts of the position switches S1 (NO contact), S2 (NO contact), S3 (NC contact) and the status signal contacts of the safety relay (X102: 1/2 NC contact, X103: 1,2 NC contact) as well as the contactor K1 (NO contact).

  • Page 232: Application Upgrade

    Application upgrade Application upgrade At the converter of series b maXX (BM443X-XX2 to BM447X-XX2) the safety function „Safe stop“ is achieved via three independent switch off channels and a hardware pulse enable input (category 4 acc. to EN 954-1). However, in many ranges it is not necessary, that the „Safe Stop“ is executed in category 4. In the following, application examples are viewed, at which only two of the three switch off chan- nels are used.
  • Page 233 Safe stop m Application example 2 Application example for machine of category 3 with two switch off channels: Pulse enable and a second common switch off channel for safety relay 1 and safety relay 2. Figure 81: Version with two safety relays (BM4XXX-XX2) At this example the safety relays 1 and 2 of a position switch are set and together form the first channel.
  • Page 234 Application upgrade m Application example 3 Pulse enable and only one safety relay Figure 82: Version with a safety relay (BM4XXX-XX1) This version of converter b maXX is equipped with one safety relay only. The hardware is identic with the other converters of this series - only the second relay is not equipped. The internal relay switch off paths are combined and together form the first channel.

  • Page 235: Technical Data Safety Relay Module

    Safe stop Technical data safety relay module WARNING The following may occur, if you disregard these safety notes: m serious personal injury m death The danger is: mechanical influence by failure of safety relay. Assure, the minimum current of the contacts X102-1 and X102-2 (or X103-1 and X103-2) not falling below during operation.
  • Page 236 Technical data safety relay module m Installation of the feedback contact with permanent load Figure 83: Installation of the feedback contact with permanent load Permanent load e.g.: Housing: Phoenix Contact, EMG12-B2 Part No.: 2948306 Transparent cover: Phoenix Contact, BMG12-H 7,5 mm Part No.: 2947116 Resistor: 1,2 kΩ...

  • Page 237: Prototype Test Certificate Bgia

    Safe stop Prototype Test Certificate BGIA ® Manual b maXX BM4400 Document No. 5.04043.06 of 248...
  • Page 238 Prototype Test Certificate BGIA ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 239: Supplement For The Test Certificate 2005 21349

    Safe stop Supplement for the test certificate 2005 21349 The series b maXX® (BM443X to BM446X) fulfills the requirements of the category 4 as well as the category 3 according to EN 954-1 provided that the circuit-technical implementation com- plies with the demands ZE.6 Application upgrade–...
  • Page 240 Supplement for the test certificate 2005 21349 ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 241: Table Of Figures

    Table of figures Table of figures Power unit (A) - controller unit (B)....................Slot combinations........................Danger areas BM441X, BM442X, BM443X and BM444X ............Danger areas BM445X, BM446X and BM447X ................. Position of type key label ......................Danger areas by the mechanical mounting................Installation space BM441X......................
  • Page 242 Table of figures Device manager in WinBASSII ....................Structure of the error list - survey ..................... Danger areas BM441X, BM442X, BM443X and BM444X............Danger areas BM445X, BM446X and BM447X................ Demounting scheme......................... Derating of output apparent power against the installation altitude.......... Derating of the output current BM 441X basic unit ..............

  • Page 243: Index

    Index Numerics Controller unit versions Cooling type 73/23/EWG Cover Current grading Current limit reached Absolute minimum voltage Accessories Danger areas 32, 137 Dangers 11, 24 b maXX® 4400 DC link BM44XX - Cable protection DC-link BM44XX - Device protection connect Declaration by Manufacturer Cable Declaration of Conformity...
  • Page 244 Index Fuses 67, 212 Non-electrical data Hardware type HIPERFACE Operating concept Operating program Operating sequence of installation I/O plug-in modules Operating software IEC 60204-1 Operating status Inappropriate use Operation Inspection intervals Option module Installation Optional modules electrical mains Overview preconditions Installation space 37, 39 Interconnect the devices...
  • Page 245 Index Safety fuses WEEE, 2002/96/EG Safety instructions 11, 24, 101 WinBASS II 96, 108 Safety notes Safety relay 35, 70, 77, 103, 105, 115, 135, X100 Durability Screwing Screwing (UL) Screws Semiconductor fuses Servo converter Short-circuit Shutdown 143, 144 Signal level Size of cabinet Slot Slots...
  • Page 246 Index ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...

  • Page 247: Revision Survey

    Revision survey Revision survey Version Version Changing ® 5.04043.03 28.07.2005 Chapter Revision survey inserted, technical data safety relay, b maXX 4472 / 4473, interface cable RS 232, additional data water-cooled chopper resistors, instructions on hardware types XX0XX, XX1XX, XX2XX, X0XXX, X1XXX and X2XXX (type key), prototype test certification in chapter E „Safe stop“, polarity temperature sensor changed in the connection dia- grams.
  • Page 248 Notes: ® Manual b maXX BM4400 Document No. 5.04043.06 Baumüller Nürnberg GmbH of 248...
  • Page 250 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.

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