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Baumuller b maXX 5000 Series User Manual

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

Table of Contents

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Baumuller b maXX 5000 Series Specifications

General IconGeneral
Seriesb maXX 5000
CategoryPower Supply
Protection ClassIP20
Communication InterfaceCANopen
Relative Humidity< 95 %, no condensation

Summary

General

1.1 Information on the instruction handbook

Provides essential information on handling the device and adhering to safety instructions.

1.2 Key to symbols

Explains warning notes and symbols used to indicate danger levels.

1.3 Limitation of liability

Outlines manufacturer's liability limitations regarding device usage and specifications.

1.6 Spare parts

Details the importance of using original spare parts and procurement methods.

Safety

2.3 Usage for the intended purpose

Defines the device's intended use and conditions for compliant operation.

2.4 Risk assessment according EU Directive

Details potential risks (electrical, thermal, mechanical) and necessary precautions according to EU directives.

2.7 Training of the personnel

Details required qualifications for operating, maintaining, and installing the device.

2.8 Personal protective equipment

Lists necessary personal protective equipment (clothing, hard hat, shoes, gloves, eyewear).

2.9 Special hazards

Identifies electrical current and residual energy hazards, including warnings and precautions.

2.12 Conduct in case of danger or accidents

Outlines preventive measures and response procedures for dangers or accidents.

Technical Data

3.1 Dimensions

Shows main dimensions of devices in millimeters and provides guidance for control cabinet space.

3.1.1 BM503X dimensions

Provides dimensional drawings for BM503X-C/-S variants.

3.1.2 BM504X dimensions

Provides dimensional drawings for BM504X-C/-S variants.

3.1.3 BM517X dimensions

Provides dimensional drawings for BM517X-C/-S variants.

3.1.4 BM519X dimensions

Provides dimensional drawings for BM519X-S and BM519X-F variants.

3.1.5 BM53XX dimensions

Provides dimensional drawings for BM532X, BM533X, and BM537X variants.

3.3 Operating conditions

Details requirements for power supply, control voltage, environmental conditions, and cooling.

3.3.1 Requirements for power supply / mains supply system

Specifies mains supply requirements, voltage, frequency, and overvoltage categories.

3.3.4 Required environmental conditions

Lists transport, storage, operating environment, humidity, vibration, and contamination requirements.

3.3.5.1 Correction values for the output current of the mains inverter BM50XX, BM51XX

Explains derating for output current based on installation altitude and temperature.

3.3.5.3 Correction values input voltage

Details derating for output current and power based on input voltage variations.

3.4 Electrical data

Provides detailed electrical specifications for BM50XX, BM51XX, BM53XX, and BM537X series.

3.4.1 Electrical data BM50XX; BM51XX

Lists electrical data for BM50XX/BM51XX mains rectifiers, including power, current, voltage, and loss.

3.4.2 Electrical data of the BM53XX

Provides electrical specifications for BM53XX axis units, including power, current, and voltage ratings.

3.4.3 Output frequency-dependent current derating

Explains how output current is reduced at static inverter frequencies below 15 Hz.

3.4.5 Proposal for dimensioning

Provides recommendations for fuse, line filter, power choke, and cable selection based on device and current.

Design and Operation

4.1 Design

Describes the b maXX 5000 series components: mains rectifier, active mains rectifier, and axis units.

4.2 Identification of the device

Explains how to identify the device using part numbers and type codes.

4.2.3 Type code

Explains the format and meaning of the BM5XXX type code components.

4.4 Display and operating elements

Details the LED displays, 7-segment displays, and address switches for BM50XX, BM51XX, and BM53XX.

4.4.1 LED display BM5XXX-XX0X-... without safety function

Explains the meaning of LEDs H1-H4 for mains rectifier unit status and errors.

4.4.2 Display and operating elements BM51XX

Describes the service interface, 7-segment display, LEDs, and address switches for BM51XX.

4.4.3 Display and operating elements BM53XX

Details service interface, 7-segment displays, LEDs, and address switches for BM53XX.

4.4.5 Setting the IP address with address switches

Guides on setting the IP address using address switches for EtherCAT®, VARAN, and POWERLINK®.

Transport and Packaging

5.1 Safety notes for transport

Provides warnings regarding unauthorized transport and physical impact, emphasizing trained personnel.

5.3 Transport inspection

Instructs on examining delivered goods for completeness and transport damage, and handling claims.

Mounting

6.1 Safety notes

States that mounting must be performed by qualified personnel, detailing necessary qualifications.

6.2 Preparing for mounting

Advises on planning, drilling patterns, and preventing conductive contamination during preparation.

6.2.1 Drilling pattern

Provides drilling patterns and tolerance specifications for air-cooled versions.

6.3 Mounting instructions

Describes general mounting procedures, including the use of lifting equipment and checking surfaces.

6.3.1 Mounting with mounting rail

Illustrates the procedure for mounting devices using a mounting rail and lists required hardware.

6.3.3 Mounting of the DC link bar

Provides guidelines for correctly mounting the DC link bar and its components.

6.4 Mounting of toroidal cores

Details the necessity and drilling pattern for mounting toroidal cores, especially for BM51XX.

Installation

7.1 Safety notes

Emphasizes that installation must be by qualified personnel and lists necessary qualifications.

7.3 Demands on the electrical mains

Warns about deviations from mains requirements, potential device damage, and operation in industrial networks C3.

7.4 Requirements for the connection cables

Specifies requirements for cable selection, protective ground conductor, and copper wire types according to standards.

7.6 PE connection and RCD compatibility

Discusses leakage current implications and the requirement for Type B RCDs or alternative protective measures.

7.7 Grounding concept of the side-by-side mounted system

Illustrates grounding concepts for devices mounted side-by-side, including PE connections.

7.8 Installation requirements with regard to EMC

Provides crucial information on EMC-compliant installation, including cable routing, component placement, and shielding.

7.10 Avoid bearing currents

Explains the causes of bearing currents and recommends measures like grounding systems and toroidal cores.

7.12 Installation procedure

Provides a step-by-step guide for installing the device, including electrical connections and safety checks.

7.13 Connection diagrams

Presents connection diagrams for electrical mains, motor, and front side connections for various BM5XXX models.

7.13.1 Connection diagram of BM50XX-XX0X-... mains rectifier without safety function

Shows the connection diagram for BM50XX-XX00 and BM50XX-XX01 mains rectifiers.

7.13.2 Connection diagram for the BM51XX active mains rectifier unit

Illustrates the connection diagram for the BM51XX active mains rectifier unit.

7.13.3 Connection diagram single axis unit

Displays connection diagrams for single axis units BM5326, BM5327, BM5328, BM5334, BM5335, and BM537X.

7.13.4 Connection diagram for the double axis unit

Shows connection diagrams for double axis units BM5323, BM5325, BM5331, BM5332, BM5333.

7.14 Electrical connections

Details electrical connections for various BM5XXX series devices, including mains, motor, and signal bus connections.

7.14.1 Electrical connections of the BM50XX-XX0X-... without safety function

Illustrates electrical connections for BM50XX-XX0X mains rectifiers.

7.14.2 Electrical connections of the BM51XX

Shows electrical connections for BM51XX devices.

7.14.3 BM519X connections

Details electrical connections for BM519X devices.

7.14.7 Electrical connections of the double axis BM5323, BM5325

Illustrates electrical connections for BM5323 and BM5325 double axis units.

7.14.8 Electrical connections of the double axis BM5331, BM5332, BM5333

Details electrical connections for BM5331, BM5332, and BM5333 double axis units.

7.14.9 Connection data

Provides connection data, torque, and load capacity for various power supply, PE, and DC link connections.

7.15 Connections on the front side

Describes connections on the front side for mains rectifier, active mains rectifier, and axis units, including fieldbus and I/O.

7.15.1 Front side of mains rectifier unit BM50XX-XX0X-... without safety function

Details front side connections for BM50XX without safety function, including X1 digital inputs/outputs.

7.15.2 Front side of active mains rectifier BM51XX

Shows front side connections for BM51XX, including service interface and digital inputs/outputs.

7.15.3 Front side axis units BM53XX

Illustrates front side connections for BM53XX axis units, including service interface, fieldbus, and add-on modules.

Operation

8.1 Operating concept

Describes device operation after commissioning and parameterization using pulse enable and quick stop signals.

8.1.1 Release signals

Explains the function and requirements of pulse enable and quick stop signals.

8.2 Timing diagrams BM50XX

Illustrates timing diagrams for quick discharge, brake resistor switching, and power supply sequences.

8.3 Monitoring

Explains how the controller monitors the device for errors or warnings via LEDs and display messages.

8.3.1 Monitoring BM50XX

Describes error messages and LED indicators for BM50XX devices without safety functions.

8.3.2 Monitoring BM51XX, BM53XX

Explains warning and error messages, and LED indicators for BM51XX and BM53XX devices.

8.4 Fieldbus communication

Covers fieldbus systems like EtherCAT®, VARAN, CANopen®, and POWERLINK®, including setup and commissioning.

8.4.1 EtherCAT®

Details EtherCAT® configuration, mounting, commissioning, and address switch settings.

8.4.2 VARAN

Explains VARAN communication, mounting, commissioning, address switch settings, and parameters.

8.4.3 CANopen®

Covers CANopen® communication, mounting, commissioning, address switch settings, and parameter settings.

8.4.4 POWERLINK®

Describes POWERLINK® communication, mounting, commissioning, address switch settings, and parameters.

Maintenance

9.1 Environmental condition

Specifies essential environmental conditions for maintenance-free operation.

9.2 Inspection intervals - maintenance notes

Outlines preventive maintenance schedules and check points for daily and periodic inspections.

9.2.1 Mechanical parts

Lists inspection checks for mechanical components like noises, screws, and part condition.

9.2.2 Power supply

Details inspection checks for power supply components like screws, deformation, and dust.

9.2.3 Connections and circuitry of the mains power supply

Guides on inspecting wiring for overheating indicators and insulation damage.

9.2.4 Transformer and chokes in the main circuit

Advises on checking for abnormal vibrations or odors in transformers and chokes.

9.2.5 Solenoid switch and relay in the power supply circuit

Specifies inspection for loose screws and switch function in the power supply circuit.

9.2.6 Plug connectors in the power supply circuit

Details inspection of plug connectors for looseness, odors, damage, or leaks.

9.2.7 Cooling system fans

Covers inspection of cooling fans for noise, vibrations, and loose screws.

9.2.8 Cooling system ventilation duct

Advises visual inspection of ventilation ducts for obstructions.

9.2.9 Safety function

Specifies checking the DC-link voltage in STO state.

9.3 Repairs

Provides contact information for device damage and repair inquiries.

Troubleshooting and Fault Correction

10.1 Behavior in case of malfunctions

Outlines basic information on device behavior during malfunctions and risks associated with improper correction.

10.2 Monitoring functions

Explains various monitoring functions and their corresponding warnings/errors for BM50XX, BM51XX, and BM53XX.

10.2.1 Monitoring function - explanations BM50XX

Details monitoring functions like power supply voltage, phase monitoring, and overcurrent for BM50XX.

10.2.2 Monitoring function - explanations BM51XX

Describes monitoring functions for BM51XX, including power supply voltage, phase, charging, and DC link.

10.2.3 Monitoring function - explanations BM53XX

Explains monitoring functions for BM53XX, covering ground fault, overcurrent, DC link, temperature, and position controller.

10.3 Error detection

Explains how errors are indicated via LEDs and 7-segment displays for BM50XX and BM51XX/BM53XX.

10.3.1 BM50XX error detection

Details error signaling through LEDs H1-H4 and the 7-segment display for BM50XX.

10.3.2 BM51XX and BM53XX error detection

Explains error signaling via LEDs H14/H24 and the 7-segment display for BM51XX/BM53XX.

10.4 Error handling

Describes predefined error reactions and methods for acknowledging errors.

10.4.1 Error acknowledgment of BM50XX

Explains how to acknowledge errors via digital input X1:4 or by power cycling for BM50XX devices.

10.4.2 Error acknowledgment of BM51XX and BM53XX

Lists methods for error acknowledgment for BM51XX and BM53XX, including digital input and pulse enable.

Accessories and Spare Parts

11.1 Cabling

Provides information on device mains cabling, motor cables, hybrid cables, and fieldbus cables.

11.1.1 Device - mains cabling

Details cross-section, length, and connection types for device mains cabling.

11.1.2 Cable device - motor

Specifies requirements for motor cables, including cross-section, length, and shielding.

11.1.3 Hybrid cable device-encoder-motor

Lists part numbers for hybrid cables with HIPERFACE® DSL® encoders for various current ratings and lengths.

11.1.6 EtherCAT®, VARAN, POWERLINK® cable

Lists available Ethernet connecting cables (patch cable, STP) with types, lengths, and part numbers.

11.1.9 Encoder cables

Lists part numbers for various encoder cables (Resolver, HIPERFACE®, Sine/square wave).

11.1.9.1 Connecting cable for Resolver

Details materials and pin assignments for making a connecting cable for Resolver encoders.

11.1.9.2 Connecting cable for encoder with HIPERFACE®

Provides instructions and materials for making a connecting cable for HIPERFACE® encoders.

11.1.9.3 Connecting cable for encoder with EnDat® or SSI

Lists materials and pin assignments for connecting cables for EnDat® or SSI encoders.

11.1.9.4 Connecting cable for encoder with EnDat® 2.2

Details materials and pin assignments for connecting cables for EnDat® 2.2 encoders (M12 and speedtec® M23).

11.1.9.5 Connecting cable for sine/square-wave incremental encoder

Provides instructions and materials for making connecting cables for sine/square-wave incremental encoders.

11.2 Fuses

Explains fuse types for cable protection and device protection, including semiconductor fuses.

11.2.1 BM5030

Lists semiconductor fuses for BM5030 devices.

11.2.2 BM5031, BM5032

Lists semiconductor fuses for BM5031 and BM5032 devices.

11.2.3 BM5043, BM5044

Lists semiconductor fuses for BM5043 and BM5044 devices.

11.2.4 BM5173, BM5174

Lists semiconductor fuses for BM5173 and BM5174 devices.

11.2.5 BM5192, BM5193

Lists semiconductor fuses for BM5192 and BM5193 devices.

11.3 Brake resistors

Details brake resistor types, electrical data, and selection criteria based on motor output and cycle.

11.3.1 Fixed tube resistors

Lists fixed tube resistors with their specifications including resistance, output, dimensions, and part numbers.

11.3.2 Fixed frame resistors

Lists fixed frame resistors with their specifications including resistance, output, dimensions, and part numbers.

11.4 Line filters

Provides block diagrams, type codes, and selection guidance for mains filters.

11.4.1 Baumüller mains filter type code

Explains the structure and meaning of the Baumüller mains filter type code.

11.4.2 Selection of the mains filter

Guides the selection of mains filters based on TN systems and IT systems, considering rated current.

11.5 Power chokes

Explains the requirement and selection criteria for power chokes, including calculation of inductance and uk values.

11.5.1 Power choke BM50XX

Provides electrical data, dimensions, and part numbers for BM50XX power chokes.

11.5.2 Power chokes for BM51XX

Lists permitted power chokes for BM51XX devices with their specifications.

11.6 Spare parts

Lists plug connectors, accessories kit shielding, and ribbon cable brackets.

11.6.1 Plug connectors

Details plug connectors for mains rectifier units and axis units, including part numbers.

11.6.2 Accessories kit shielding

Lists accessories kit shielding for air-cooled/water-cooled and cold plate devices.

11.7 Connection rails

Lists parts for DC link bars, mounting rails, and PE connection kits.

11.8 Toroidal cores

Explains the use of toroidal cores for reducing bearing currents and provides recommendations for different motor/axis unit combinations.

Shutdown, Storage

12.1 Safety instructions

Provides safety instructions for decommissioning and storing the device, emphasizing qualified personnel.

12.3 Shutdown

Outlines the steps for safely shutting down the device, including off-circuiting and checking isolation.

12.4 Demounting

Describes the demounting process, including safety precautions related to sharp edges and lifting.

12.5 Storage conditions

Specifies environmental conditions and capacitor reforming procedures for proper storage.

12.6 Recommissioning

Guides on recommissioning the device, referring to mounting and installation procedures.

Disposal

13.1 Safety regulations

Covers safety regulations related to disposal, including electrical hazards and environmental protection.

13.2 Disposal facilities/authorities

Advises on complying with company policies and national regulations for proper disposal.

Appendix A - Abbreviations

Appendix B - Declaration of Conformity

EU-Declaration of Conformity

Provides the EU Declaration of Conformity according to EMC and Low Voltage Directives.

Applied harmonized standards

Lists harmonized standards applied for the device's conformity.

Appendix C - BM5030 with Safety Function

C.1 Approvals, directives and standards

Lists safety engineering standards, area of application, and approvals for the BM5030 safety function.

C.2 Function

Explains the function of the mains rectifier BM5030 with safety function, including STO capability.

C.3 Electrical data BM5030 with safety function

Provides detailed electrical specifications for the BM5030 with safety function.

C.4 LED display BM5030 with safety function

Explains the meaning of LEDs H1-H6 on the BM5030 with safety function.

C.5 Connection diagram BM5030 with safety function

Shows connection diagrams for the BM5030 with safety function, including STO function and power supply.

C.6 Electrical connections BM5030 with safety function

Details electrical connections for the BM5030 safety function, including X1 and X2 interfaces.

C.6.1 Connection data of BM5030 with safety function

Provides connection data, torque, and load capacity for power supply, DC link, and X101/X200.

C.6.2 Connections front side BM5030 with safety function

Details the pin assignment and description for digital inputs/outputs on the front side X1.

C.7 Description of the safety function STO

Covers safety-related characteristics of the STO function, including PFH, HFT, PL, and MTTF_D.

C.7.1 Safety related characteristics of the STO function

Lists safety integrity levels and performance levels according to relevant standards.

C.7.2 Reaction time STO

Specifies reaction times for STO function and precautions regarding DC link discharge.

C.7.3 Cycle time STO

Explains the cycle time STO and provides timing diagrams for various states.

C.7.4 Safety function STO im BM5030-XX2X-...

Describes the STO switch check and state change conditions for BM5030-XX2X.

Overview of Revisions

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