Baumuller BM4-F-AIO-01, BM4-F-AIO-02, BM4-F-AIO-03, BM4-F-AIO-04 Instruction Handbook Manual

Download

Instruction handbook

Language English

Translation Document No. 5.01045.08 Part No. 372665 Status 12-Dec-2014

5.01045.08

b maXX

BM4-F-AIO-XX AIO-XX

Analog IO module

BM4400, BM4400 ES BM4600, BM4600 ES BM4700, BM4700 ES

Read the Manual before starting any work!

use. This Instruction handbook may not be copied or reproduced, in whole or in part, for any other purposes. The use and disclosure of information contained in this Instruction handbook are not permitted. Designations and company marks contained in this Instruction handbook could be trademarks, the use of which by third parties for their own purposes could violate the rights of the rights holder.

Preliminary information

Warning Insofar as this document is identified as being preliminary information, the following applies: This version is regarded as providing advance technical information to users of the described devices and their functions at an early enough time in order to adapt to any possible changes or expanded functionality. This information must be regarded as being preliminary, as it has not yet passed through Baumüller's internal review process. In particular, this information is still subject to changes, thus no legal liability can be derived from this preliminary information. Baumüller assumes no liability for damages that might arise from this possibly faulty or incomplete version. If you detect or suspect any content errors and/or major form errors in this preliminary information, we request that you notify the Baumüller support specialist responsible for you. Please provide us, via this employee, with your insights and comments so that we can take them into account and include them when transitioning from the preliminary information to the final information (as reviewed by Baumüller). The conditions stipulated in the following section under „Obligatory“ are invalid in case of preliminary information.

Obligatory This Instruction handbook are a part of the equipment/machine. This Instruction handbook

must be available to the operator at all times and must be in legible condition. If the equip ment/machine is sold or moved to another location, this Instruction handbook must be passed on by the owner together with the equipment/machine. After any sale of the equipment/machine, this original and all copies must be handed over to the buyer. After disposal or any other end use, this original and all copies must be destroyed.

When the present Instruction handbook is handed over, corresponding sets of Instruction handbooks of a previous version are automatically invalidated. Please note that the specifications/data/information are current values according to the printing date. These statements are not legally binding with regard to measurements, computation or calculations. Baumüller Nürnberg GmbH reserves the right, in developing its products further, to change the technical specifications and handling of it products concerned without prior notice.

No liability can be accepted concerning the correctness of this Instruction handbook unless otherwise specified in the General Conditions of Sale and Delivery.

 Baumüller Nürnberg GmbH

Ostendstr. 80 - 90 90482 Nuremberg Germany

Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30

Email: mail@baumueller.de Internet: www.baumueller.de

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Information on this Instruction handbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.10 Used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.11 List of associated documentations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Contents of the Instruction Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Use, compliant with intended purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.6 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.7 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.8 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.9 Behavior in hazardous situations or at accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.10 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 Power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.3 Input linearity error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.4 Operation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.2 BM-F-AIO-XX for standard controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2.1 Slots BM4-F-AIO-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2.2 Type plate BM4-F-AIO-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2.3 Type code BM4-F-AIO-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.2.4 Danger areas BM4-F-AIO-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . 26

4.3 AIO-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.3.1 Position AIO-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.3.2 Type plate AIO-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.3.3 Type code AIO-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 Display and operation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.2 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

Table of contents

6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1 Preparation of mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.2 Requirements on the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.3 Requirements for the connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.4 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.5 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.6 Internal circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.6.1 Internal circuit diagram of Analog-IO-Modules (BM4-F-)AIO-01/-02/-03 . . . . . . . . . . 41

7.6.2 Internal circuit diagram of Analog IO module (BM4-F-)AIO-04 . . . . . . . . . . . . . . . . . 42

8 Commissioning/Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.2 Procedure of the commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2.1 Recognition of the Analog IO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2.2 Testing of the Analog IO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.2.2.1 Testing of inputs AIO-01, -02 and -03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.2.2.2 Testing of inputs AIO-04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.2.2.3 Testing of outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.2.3 Offset adjustment of an analog input channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.2.3.1 Offset adjustment of AIO-01, -02, -03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.2.3.2 Offset adjustment AIO-04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.2 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.3 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

10 Troubleshooting and Fault correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.2 Fault detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10.3 Error handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

10.3.1 Error reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

10.3.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

11 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

11.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

11.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Appendix A - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Table of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

1.1 Information on this Instruction handbook

The AIO-XX or BM4-F-AIO-XX can be operated in combination with a b maXX 4000, only.

Therefore this Instruction handbook is an addition to the Instruction handbook of b maXX BM4400, BM4400 ES, BM4600, BM4600 ES, BM4700, BM4700 ES (short b maXX 4000)

5.12008. The basic prerequisite for safe working is compliance with all the safety and handling in-

structions stated in the instruction handbook b maXX 4000. Additionally, the valid accident prevention regulations and general safety regulations ap-

plicable to the scope of application the device must be complied with. Read this Instruction handbook and the Instruction handbook b maXX 4000, particularly

the safety notes chapter, completely before beginning any work on the device. This In struction handbook is part of the product and must be kept accessible to personnel at all times in the immediate vicinity of the device.

1GENERAL

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

1.2

Key to symbols

1.2 Key to symbols

Warning notes

Warning notes are identified by symbols in this Instruction handbook. The notes are introduced by signal words that express the extent of the danger.

It is imperative that these notes be complied with and are conscientiously regarded in order to prevent accidents, personal injury and material damage.

DANGER!

....this indicates a hazardous situation which, if not avoided, will result in death or se-

rious injury.

WARNING!

....this indicates a hazardous situation which, if not avoided, could result in death or

serious injury.

Recommendations

CAUTION!

....this indicates a hazardous situation which, if not avoided, could result in minor or

moderate injury.

NOTICE!

....indicates a hazardous situation which, if not avoided, may cause material damage.

NOTE!

....highlights useful hints and recommendations, as well as information for the effi-

cient and trouble-free use.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

1.3 Limitation of liability

All specifications and notes in these instruction handbook were compiled taking into account the applicable standards and regulations, the state of the art and our knowledge and experience of many years.

The manufacturer assumes no liability for damages due to:

m noncompliance with the instruction handbook m usage for other than the intended purpose m usage by untrained personnel

The actual scope of delivery can vary in case of optional equipment, laying claim to additional order options, or on account of the latest technical changes to the explanations and representations described herein.

The user bears the responsibility for performing service and initial operation in accordance with the safety regulations of the applicable standards and all other relevant governmental or local regulations concerning the dimensioning and protection of conductors, grounding, disconnectors, overcurrent protection, etc.

The person who carried out the mounting or installation is liable for any damage incurred when assembling or connecting the device.

General

1.4 Copyright protection

The instruction handbook must be treated confidentially. It is to be used exclusively by personnel who work with the device. The consignment of the instruction handbook to third persons without the written permission of the manufacturer is prohibited.

NOTE!

The specific contents, text, drawings, images and other representations are copyrighted and subject to industrial property rights. Any prohibited usage is punishable by law.

CANopen

EnDat

EtherCAT

Hiperface SinCos

is a registered trademark of CAN in Automation e.V

is a registered trademark of Dr. Johannes Heidenhain GmbH, 83301 Traunreut, Germany

is a registered trademark of Beckhoff Automation GmbH, 33415 Verl, Germany

is a registered trademark of SICK STEGMANN GmbH, 78166 Donaueschingen, Germany

NOTE!

Please note, that BAUMÜLLER is not responsible to examine whether any (industrial property) rights of third parties are infringed by the application-specific use of the BAUMÜLLER products/components or the execution.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

1.5

1.5 Other applicable documents

Components of other manufacturers are integrated into the device. For these purchased parts, hazard assessments have been performed by the respective manufacturers. The compliance of the design construction with the applicable European and national regula tions has been declared for the components by the respective manufacturers.

1.6 Spare parts

WARNING!

False or flawed spare parts can lead to damage, malfunction or complete failure, thus endangering safety.

Therefore: m Only use original spare parts of the manufacturer.

Procure spare parts through an authorized dealer or directly from the manufacturer.

1.7 Disposal

Insofar as no take-back or disposal agreement has been made, please disassemble units correctly and properly recycle the constituent parts.

See also b maXX 4000 5.12008, chapter Disposal.

1.8 Guarantee provisions

The guarantee provisions are stated in a separate document of the sales documents. The devices described herein may only be operated in accordance with the stipulated

methods, procedures and conditions. Anything else not presented here, including the op eration of devices in mounted positions, is not permitted and must be cleared with the plant on a case-by-case basis. If the devices are operated in any other manner than as described within this Instruction handbook, then all guarantee and warranty rights are ren dered null and void.

1.9 Customer service

of 82

Our customer service is available to provide you with technical information. Info on the responsible contact persons is available at all times via telephone, fax, mail or

the Internet.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

1.10 Used terms

The term function module or the designation AIO-XX (ES controller) or BM4-F-AIO-XX (standard controller) is also used in this documentation for the Baumüller product „b

maXX analog IO module“. A list of the abbreviations used can be found in b maXX

4000 5.12008, Appendix A: Abbreviations.

1.11 List of associated documentations

Instruction handbook

Instruction Handbook basic unit b maXX 4400, 4600, 4700 (ES) 5.12008 444495 444496

Parameter manual

General

Doc No. Part No.

German

Part No.

English

Instruction handbook function modules

Instruction handbook option modules

Doc No. Part No.

Parameter manual basic unit b maXX 4400, 4600, 4700 (ES) 5.03039 376339 377548

Doc No. Part No.

Analog IO module BM4-F-AIO-XX or AIO-XX 5.01045 354844 372665

Digital IO module BM4-F-DIO/FIO-XX or DIO/FIO-XX 5.01046 354843 372666

Encoder module BM4-F-ENC-XX or ENC-XX 5.01042 354842 372861

Incremental encoder emulation module BM4-F-IEE-XX or IEE-XX 5.02020 354858 376728

SSI encoder emulation module BM4-F-SIE-XX or SIE-XX 5.03056 377123 379049

Doc No. Part No.

DISC-NT slave BM4-O-DNT-XX 5.03007 367670 -

CANopen slave BM4-O-CAN-03 5.02014 368692 368693

CANopen slave programming handbook for controller 5.02065 368694 372860

CANopen over EtherCAT programming handbook 5.07017 413208 432414

CANopen slave for b maXX PLC application handbook 5.03057 376486 376487

b maXX drive PLC 5.01051 366197 354845

b maXX drive PLC application handbook 5.02004 366198 372017

BM4-O-ETH-01, BM4-O-ETH-02, BM4-O-CAN-04 for b maXX PLC 5.03001 366202 372042

BM4-O-ETH-01, BM4-O-ETH-02, BM4-O-CAN-04 CANopen master for

maXX PLC application handbook

CANsync master for b maXX PLC 5.02056 366199 372025

CANsync slave for b maXX 5.02064 366201 372041

CANsync for b maXX PLC application handbook 5.02066 366200 372039

IEI for b maXX PLC 5.02013 366204 372044

PROFIBUS-DP slave for b maXX 5.03040 376488 376489

PROFIBUS-DP slave for b maXX PLC application handbook 5.03058 376490 376491

PROFIBUS-DP slave for b maXX controller programming handbook 5.03045 376757 377294

5.03002 366203 372043

German

Part No.

English

Part No.

English

Part No.

English

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

1.11

List of associated documentations

Doc No. Part No.

SERCOS slave module BM4-O-SER-01 5.04012 380910 381069

SERCOS slave module BM4-O-SER-01 parameter handbook 5.04013 381652 381653

EtherCAT slave module BM4-O-ECT-01/ECT-01 5.06003 394953 394954

Ethernet with EtherCAT master for b maXX drive PLC 5.07001 407996 407997

Ethernet with EtherCAT master for b maXX drive PLC application handbook 5.07002 407998 407999

Ethernet with EtherCAT for b maXX drive PLC 5.10018 433997

POWERLINK Controlled Node BM4-O-PLK-01/PLK-01 ES 5.12072 444497 444498

POWERLINK Controlled Node BM4-O-PLK-01 ES application handbook 5.13013 445131 445132

German

Part No.

English

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

This section provides an overview of all of the important safety aspects for optimum protection of personnel as well as for the safe and problem-free operation.

2.1 Contents of the Instruction Handbook

Each person who is tasked with performing work on or with the device must have read and understood this Instruction Handbook and the Instruction Handbook of b maXX 4000

5.12008 before working with the device. This also applies if the person who is involved with this kind of device or a similar one, or has been trained by the manufacturer.

2.2 Changes and modifications to the device

In order to prevent hazards and to ensure optimum performance, no changes, additions or modifications may be undertaken on the device that have not been explicitly approved by the manufacturer.

2SAFETY

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

2.3

Use, compliant with intended purpose

2.3 Use, compliant with intended purpose

The BM4-F-AIO-XX is used compliant with its intended purpose, if it is built-in/operated within b maXX 4000 controller, only.

The Analog IO module is considered as being used compliant with its intended purpose if all notes and information of this Instruction handbook and the Instruction handbook

b maXX 4000 5.12008 are adhered to.

WARNING!

Danger arising from usage for an unintended purpose!

Any usage that goes beyond the intended purpose and/or any non-compliant use of the device can lead to dangerous situations.

Therefore:

m Only use the Analog IO module compliant with its intended purpose. m Note all specifications of this Instruction handbook and the Instruction handbook

b maXX 4000 5.12008.

m Ensure that only qualified personnel work with/on this Analog IO module. m When configuring, ensure that the Analog IO module is always operated within its

specifications.

m The Analog IO module may only be operated in a technically flawless condition. m Only operate the Analog IO module in combination with components approved by

Baumüller Nürnberg GmbH.

2.4 Responsibility of the operating company

The device will be used in commercial areas. Thus, the proprietor of the device is subject to the legal work safety regulations.

Along with the notes on work safety in this Instruction handbook and the Instruction handbook b maXX 4000 5.12008, the safety, accident prevention and environmental protection regulations valid for the area of application of this device must be complied with. Whereby:

m The operating company must inform himself about the applicable work health and safe-

ty regulations and ascertain, in a hazard assessment, any additional hazards that could arise from the special working conditions in the use area of the device. These must then be implemented in the form of operating instructions for operation of the device.

m This Instruction handbooks must be kept accessible to personnel working with the de-

vice at all times in the immediate vicinity of the device.

m The specifications of the Instruction handbooks must be adhered to completely and

without exception.

m The device may only be operated in a technically faultless and operationally safe con-

dition.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

2.5 Training of the personnel

WARNING!

Risk of injury due to insufficient qualifications!

Improper handling can lead to significant personal injury and material damage. Therefore:

m Certain activities can only be performed by the persons stated in the respective

chapters of this Instruction handbook.

In this Instruction handbook, the following qualifications are stipulated for various areas of activity:

m Operating personnel

n The drive system may only be operated by persons who have been specially trained,

familiarized and authorized.

n Troubleshooting, maintenance, cleaning, maintenance and replacement may only

be performed by trained or familiarized personnel. These persons must be familiar with the Instruction handbook and act accordingly.

n Initial operation and familiarization may only be performed by qualified personnel.

Safety

m Qualified personnel

n Electrical engineers authorized by Baumüller Nürnberg GmbH, and qualified electri-

cians of the customer or a third party who have learned to install and maintain Baumüller drive systems and are authorized to ground and identify electrical power circuits and devices in accordance with the safety engineering standards of the com pany.

n Qualified personnel have had occupational training or instruction in accordance with

the respective locally applicable safety engineering standards for the upkeep and use of appropriate safety equipment.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

2.6

Special hazards

2.6 Special hazards

In the following section, the remaining marginal risks will be stated that have been identified as a result of the hazard analysis.

Observe the safety notes listed here and the warning notes in the further chapters of this manual to reduce health risks and dangerous situations.

Electrical current

DANGER!

Risk of fatal injury from electrical current!

There is an immediate risk of fatal injury if live electrical parts are contacted. Damage to the insulation or individual components can be life-threatening.

Therefore:

m Switch off the electrical power immediately in case of damage to the power supply

m Only allow work on the electrical system to be performed by qualified personnel. m Switch off the current when any kind of work is being performed on the electrical

insulation.

system and ensure safety before switching on again.

Danger from residual energy

DANGER!

Risk of fatal injury from electrical current!

Stored electric charge. Discharge time of the system = discharge time of the device with the longest DC link

discharge time connected to the DC link. See Instruction handbook b maXX 4000 5.12008, chapter Electrical Data. Therefore:

m Do not touch electrically live parts before taking into account the discharge time of

the capacitors.

m Pay attention to the corresponding notes on the device. m If additional capacitors are connected to the DC link, the DC link discharge can

take a much longer time. In this case, the necessary waiting period must itself be determined or a measurement made as to whether the equipment is de-energized. This discharge time must be posted, together with an IEC 60417-5036 (2002-10) warning symbol, on a clearly visible location of the control cabinet.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Moving components

2.7 Fire fighting

Safety

WARNING!

Risk of injury from moving components!

Rotating components and/or components moving linearly can result in severe injury. Therefore:

m Do not touch moving components during operation. m Do not open any covering during operation. m The amount of residual mechanical energy depends on the application. Powered

components still turn/move for a certain length of time even after the power supply has been switched off. Ensure that adequate safety measures are taken.

DANGER!

Risk of fatal injury from electrical current!

There is a risk of electric shock if an electrically-conductive, fire-extinguishing agent is used.

Therefore: m Use the following fire-extinguishing agent:

ABC powder / CO

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

2.8

Safety equipment

2.8 Safety equipment

WARNING!

Risk of fatal injury due to non-functional safety equipment!

Safety equipment provides for the highest level of safety in a facility. Even if safety equipment makes work processes more awkward, under no circumstances may they be circumvented. Safety can only be ensured by intact safety equipment.

Therefore: m Before starting to work, check whether the safety equipment is in good working or-

der and properly installed.

2.9 Behavior in hazardous situations or at accidents

Preventive measures

And if something does happen: re spond properly.

m Always be prepared for accidents or fire! m Keep first-aid equipment (e.g. first-aid kits, blankets, etc.) and fire extinguishers readily

accessible.

m Familiarize personnel with accident signaling systems, first aid equipment and life sav-

ing equipment.

m Stop operation of the device immediately with an EMERGENCY Stop.

m Initiate first aid measures. m Evacuate persons from the danger zone. m Notify the responsible persons of the site. m Alarm medical personnel and/or the fire department. m Keep access routes clear for rescue vehicles.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

2.10 Signs and labels

The following symbols and information signs are located in the working area. They refer to the immediate vicinity in which they are affixed.

WARNING!

Risk of injury due to illegible symbols!

Over the course of time, stickers and symbols on the device can become dirty or otherwise unrecognizable.

Therefore: m Maintain all safety, warning and operating labels on the device in easily readable

condition.

Electrical voltage

Only qualified personnel may work in work areas that identified with this.

Safety

Unauthorized persons may not touch working materials marked correspondingly.

DANGER!

Risk of fatal injury from electrical current!

See ZDanger from residual energy– auf Seite 14.

CAUTION!

Risk of injury due to hot surface!

Therefore: m Wear protective gloves

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

2.10

Signs and labels

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

3TECHNICAL DATA

3.1 Electrical data

(BM4-F-)AIO-

01 02 03 04

Number of inputs 2

Number of IO-input links 2

Resolution 10 bit / 12 bit 16 bit 12 bit 16 bit

Design differential input circuit

Input resistance ca. 50 kΩ ca. 100 Ω

Max. input current 200 µA 20 mA

Min. input current - 4 mA

Sample rate inputs, one input used 125 µs

Sample rate inputs, both inputs used 250 µs

Max. analog input voltage - 10 V to + 10 V 2 V

Number of outputs 2

Number of IO-output links 2

Max. output current 1 mA

Resolution 8 bit 16 bit 12 bit 16 bit

Update-rate fast outputs 125 µs

Update-rate slow outputs 8 ms

Short-circuit protection output limited short-circuit protection (max. 10 s)

Analog output voltage - 10 V to + 10 V

The analog outputs can be changed from „fast output“ to „slow output“ and vice versa by the operation software.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

3.2

Power input

3.2 Power input

(BM4-F-)AIO-

01 02 03

Voltage

5,0 V 0,2 mA 4 mA 10 mA 5 mA 4 mA

3,3 V - - 160 mA 40 mA -

+15,0 V 27 mA 37 mA 20 mA 23 mA 37 mA

-15,0 V 26 mA 35 mA 19 mA 22 mA 35 mA

8,0 V - - - - -

: Displayed in ProDrive navigation „Service“

up to (BM4-F-)AIO-03-00

version C*

)

from (BM4-F-)AIO-03-01

version D*

)

3.3 Input linearity error

DNL

min

AIO-01 0 2 6 0 2 5 0 3 6 0 4 8

AIO-02 0 2 4 0 3 6 0 3 6 0 3 6

AIO-03 0 2 4 0 2 4 0 8 16 0 15 50

AIO-04 0 2 4 0 3 6 0 3 6 0 3 6

DNL

typ

DNL max

INL min

INL

typ

INL

max

Offset

min

Offset

typ

Offset

max

Gain

min

Gain

typ

Gain

max

Note: The specifications are related to the LSB of the associated module. Tolerances of offset and gain can be adjusted within the controller.

3.4 Operation conditions

The operation conditions of the b maXX 4000 5.12008 are valid.

Transportation temperature range - 25 °C bis + 70 °C

Transportation climate classification EN 60721-3-2 2 K 3

Storage temperature range - 25 °C bis + 55 °C

Storage climate classification EN 60721-3-1 1 K 4

NOTICE!

Normally, only non-conductive pollution occurs. Any conductive pollution, if for a short-term or permanently, is forbidden and can cause the destruction of the device. The customer is responsible for destructions, caused by conductive materials.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

4DESIGN AND OPERATION

A b maXX BM4000 device consists of power unit and controller part

Power unit Controller part

Figure 1: b maXX BM4000)

standard controller

Design cover (standard controller only)

Standard controller

BM4XXX-XXX-XX1XX BM4XXX-XXX-XX2XX BM4XXX-XXX-XX3XX

Controller part ES controller

ES controller

BM4XXX-XXX-XX4XX BM4XXX-XXX-XX5XX

The BM4-F-AIO-XX is designed as plug-in module within the standard controller and can be replaced or upgraded.

The AIO-XX is mounted stationary in the ES controller.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

4.1

Function

4.1 Function

The Analog IO module converts analog input signals in digital signals for control (e.g set value generation) and/or makes available converted analog values (e. play) from internally processed digital signals.

Technical data of the Analog IO module can be found in ZTechnical Data– from page

19.

NOTE!

The operation with ProDrive is described, only. Please contact Baumüller Nürnberg GmbH or visit out website www.baumueller.de for download, if the software is not available.

g. for RPM dis-

Standard controller

ES controller with not exchangeable function and option modules.

with plug-in slots to enlarge the controller functionality with function and option modules, e.g. encoder modules, analog inputs/outputs or field bus connections.

NOTICE!

Plug-in module, which has not been manufactured from Baumüller Nürnberg GmbH. Modules of other manufacturers can damage/destroy the device.

Only use BM4-F-XXX- and BM4-O-XXX-plug-in modules.

The Analog IO module is available as plug-in module BM4-F-AIO-XX for standard controller and as AIO-XX built in the ES controller.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

4.2 BM-F-AIO-XX for standard controller

The BM4-F-AIO-XX is a plug-in module for the controller of b maXX 4000-series. The BM4-F-AIO-XX plug-in module is connected to the controller with a plug on its back. On the front is a 9-pin Sub-D connector (male).

Design and Operation

Plug (back side)

Handle

Figure 2: Analog IO module for standard controller

4.2.1 Slots BM4-F-AIO-XX for standard controller

Function and option modules can be plugged in the slots of the controller part. Each position is clearly identified by a character.

The Analog IO module can be plugged in following slots:

A BM4-F-AIO-02 BM4-F-AIO-03 BM4-F-AIO-04

B BM4-F-AIO-02 BM4-F-AIO-03 BM4-F-AIO-04

C BM4-F-AIO-02 BM4-F-AIO-03 BM4-F-AIO-04

D BM4-F-AIO-02 BM4-F-AIO-03 BM4-F-AIO-04

Module identification AIO-01 AIO-02 AIO-03 AIO-04

Sub-D connector (front)

E BM4-F-AIO-01 BM4-F-AIO-02 BM4-F-AIO-03 BM4-F-AIO-04

NOTE!

At the most 2 Analog IO modules can be used.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

4.2

BM-F-AIO-XX for standard controller

Optional plug-in modules (function or option modules) can be upgraded dependent on the existing controller type.

Possible combinations function modules/option modules

Function modules Option modules

BM4-F-ENC-XX

(encoder 1 for motor control recommended)

BM4-F-ENC-XX (encoder 2)

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

BM4-F-AIO-02/03/04 (analog I/O)

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

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

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

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

BM4-F-UME-XX (mains voltage measurement)

BM4-O-SER-XX (Sercos slave)

BM4-O-PRO-01 (Profibus slave)

BM4-O-CAN-03 (CANopen slave)

BM4-O-ECT-01 (EtherCAT slave) for controller

BM4-O-PLK-01

(POWERLINK Controlled Node) für Regler

BM4-O-EIP-01 (Ethernet-IP) für Regler

BM4-O-PLC-XX (SPS)

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

BM4-O-IEI-XX* (incremental counter module)

BM4-O-ETH-01* (Ethernet)

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

BM4-O-ECT-01* (EtherCAT slave) for PLC

BM4-O-ECT-02* (Ethernet + EtherCAT master)

A X - - o o o - o o - - - - - - - - - - - - - -

B - X - o o o - X o - - - - - - - - - - - - - -

C - - - o o o V - o - - - - - - - - - - - - - -

D - - - o X X - - X - - - - - - - - - - - - - -

E - - X X o o - - - - - - - - - - - - - - - - -

F Controller unit

G - - - - - - - - - o o o o o o o X X X X X X X

H - - - - - - - - - X X X X X X X o - o o o o o

J - - - - - - - - - - P P - - - - o o o o - - -

K - - - - - - - - - - P P - - - - o o o o o o o

L - - - - - - - - - - P P - - - - o o o o o o o

M - - - - - - - - - - P P - - - - o o o o o o o

preferred slot Baumüller 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 preferred slot is occupied, we recommend in order to reach the highest functional range, to insert the plug-in modules into this slot.

only possible, if on slot G or H a PLC module (PLC) is plugged and the PLC (and not the controller) operates the communication to the field bus slave module.

BM4-O-ECT-03* (Ethernet + EtherCAT cluster)

Steckkarten_Rev20_e

of 82

dependent on controller hardware

not possible - card doesn’t work in this slot.

precondition for these cards is an inserted PLC module.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Design and Operation

NOTE!

Only 2 analog outputs can be parametrized or linked even more than one AIO module is plugged.

NOTE!

EtherCAT option modules must not be plugged in slot J of a 3-rowed controller unit, because the module can be damaged.

In case another BM4X-X-XXX plug-in module is plugged in an unsuitable slot, it will not operate. We have made sure, that neither the module nor the device are dam aged.

4.2.2 Type plate BM4-F-AIO-XX for standard controller

The type plate can be found on the connector on the back side of the BM4-F-AIO-XX. The type code and the serial No. are printed on the type plate.

Figure 3: Type plate BM4-F-AIO-XX for standard controller

Type plate

e.g.

BM4-F-AIO-01

2 analog IN \ 2 analog OUT S12345678

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

4.2

BM-F-AIO-XX for standard controller

4.2.3 Type code BM4-F-AIO-XX for standard controller

NOTE!

This type code is valid for the BM4-F-AIO-XX of series b maXX 4000 exclusively. For other plug-in modules different type codes are available.

Type code:

BM4 - F - AIO - XX - YY Device family, in which the plug-in module can be built in

BM4 - F - AIO - XX - YY Type of plug-in module (function module)

BM4 - F - AIO - XX - YY Name of plug-in module (Analog IO module)

BM4 - F - AIO - XX - YY Version plug-in module (No. of inputs/outputs)

01: 2 x 10 bit input, 2 x 8 bit output 02: 2 x 16 bit input, 2 x 16 bit output 03: 2 x 12 bit input, 2 x 12 bit output 04: 2 x 16 bit input 4 mA...20 mA, 2 x 16 bit output -10 V...+10 V

BM4 - F - AIO - 03 - YY Version hardware (AIO-03 only)

00: For BM4000 without Ethernet interface (BM44XX-XXX-XX2XX-03) 01: For all BM4000 - with Ethernet interface, too (BM44XX-XXX-XX3XX-03)

NOTE!

Please use in case of b maXX controller with Ethernet interface (type BM4XXX-XXXXX

3XX-03) only AIO-03 modules with type code BM4-F-AIO-03-01 and higher.

4.2.4 Danger areas BM4-F-AIO-XX for standard controller

The BM4-O-AIO-XX can be operated in combination with BM4000, only. Please note all safety notes of the basic unit b

maXX BM4000.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

4.3 AIO-XX in ES controller

The AIO-XX is mounted stationary in the ES controller.

Design and Operation

e.g. AIO-02 position C

AIO-01 always position E

Figure 4: AIO-XX for ES controller

The controller is ordered with the desired function/option modules, these are mounted stationary (exception slot H) and cannot be changed. Only the option module in slot H can be changed/added.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

4.3

AIO-XX in ES controller

4.3.1 Position AIO-XX in ES controller

Each position is clearly identified by a character. The AIO-XX can be used at the following position.

AIO-02 AIO-03 AIO-04

E AIO-01

F Controller

Steckkarten_ES_Rev02_e

Combinations function modules/option modules

Function modules Option modules

BM4-F-ENC-XX (encoder 1)

for motor control recommended

BM4-F-ENC-XX (encoder 2)

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

BM4-F-AIO-02/03/04 (analog I/O)

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

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

BM4-F-IEE-XX

(incremental encoder emulation)

BM4-F-SIE-XX

(SSI encoder emulation)

BM4-O-ECT-01

(EtherCAT slave) for controller

BM4-O-PLK-01

(POWERLINK Controlled Node)

for controller

BM4-O-VAR-01

(VARAN slave) for controller

BM4-O-SER-XX

(Sercos slave) for controller

BM4-O-PRO-XX

(Profibus slave) for controller

BM4-O-CAN-03

(CANopen slave) for controller

A X - - o o o - o - - - - - - - -

B - X - o o o - X - - - - - - - -

C - - - o o o X - - - - - - - - -

D - - - X X X - - - - - - - - - -

E - - F - - - - - - - - - - - - -

F Controller unit with RS232- or Ethernet interface

G - - - - - - - - X - - - - - - -

H - - - - - - - - - X X X X X X X

prefered slot

permanently installed

possible slot, only the prefered slot is occupied

not possible

BM4-O-EIP-01

(Ethernet-IP) for controller

BM4-O-PLC-XX (SPS)

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

NOTE!

Only 2 analog outputs can be parametrized or linked even more than one AIO module is available.

4.3.2 Type plate AIO-XX in ES controller

The type code of the AIO-XX is included in the type plate of the basic unit.

4.3.3 Type code AIO-XX in ES controller

The type code has the form:

Design and Operation

BM4XXX - XXX - XXXXX[Ryy] - [XXXXXXXX] - [XXX] - XX. Directly behind the type code is the version code (- XXXX - X - XXX - XXX). A module AIO-01 is available in position E, always. Only the shown section is valid for the AIO-02/03/04 in ES controller.

BM4XXX - XXX - XXXXX[Ryy] - [XXXXXX] - [XXX] - XX

4.4 Display and operation elements

Device generation

ES controller function module, position A

ES controller function module, position B

ES controller function module, position C

ES controller function module, position D

Analog IO (2 x IN, 2 x OUT), 16 bit see

Analog IO (2 x IN, 2 x OUT), 12 bit see

Analog IO (2x input 16 bit, 4-20mA / see 2x output 16 bit)

AIO-02 AIO-03 AIO-04

The encoder module provides neither operation nor display elements. The LED H4 of the basic unit b maXX BM4000 respectively the emulation of the LED in

ProDrive displays all device errors, including the errors generated concerning the Analog IO module.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

4.4

Display and operation elements

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

5TRANSPORT AND PACKAGING

5.1 What to observe when transporting

For initial transport the BM4-F-AIO-XX for standard controller is packed at the manufacturer. If the device is to be further transported, ensure that the following conditions are met throughout the entire transport:

m Climate class 2 K 3 as per EN 60721-3-2 m Temperature range - 30 °C up to + 70 °C m Vibration, shock, continuous shock class 2 M 1 as in EN 60721-3-2

5.2 Transport inspection

Upon receiving the delivered goods, immediately examine them for completeness and transport damage.

If there is outwardly visible transport damage, proceed as follows:

m Do not accept the delivery or conditionally accept it with reservations. m Note the extent of the damage on the transport documents or on the delivery note of

the transport agent.

m Immediately file a complaint with the freight carrier. Have the complaint confirmed in

writing and immediately contact the responsible representative of Baumüller Nürnberg GmbH.

NOTE!

The device may not be operated if there is visible transport damage!

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

5.3

Unpacking

5.3 Unpacking

After having received the still packaged device: h Avoid transport shocks and hard jolts, e.g. when putting an item down.

If no transport damage is visible:

h Open the packaging of the device. h Verify the delivery scope based on the delivery note.

File a claim with the responsible Baumüller representative if the delivery is incomplete.

NOTE!

Claim each individual deficiency as soon as it has been detected. Damage claims can only be validly asserted within the claim registration period.

5.4 Disposal of the packaging

The packaging consists of cardboard, plastic, metal parts, corrugated cardboard and/or wood.

h When disposing of the packaging, comply with the national regulations.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

In this chapter we describe the mechanical mounting of the plug-in module

BM4-F-AIO-XX for BM4400, BM4600, BM4700 with standard controller.

NOTE!

The AIO-XX modules are mounted stationary in the BM4400, BM4600, BM4700 with ES controller and cannot be changed, therefore no mounting is necessary!

6.1 Preparation of mounting

h Check the marking AIO-XX, whether the right plug-in module is available.

6MOUNTING

Figure 5: BM4-F-AIO-XX for standard controller

h Determine the suitable slot

(see ZSlots BM4-F-AIO-XX for standard controller– on page 23).

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

6.2

Assembly

6.2 Assembly

WARNING!

Danger as a result of faulty mounting!

The mounting requires qualified personnel with adequate experience. Faulty mounting can lead to life-threatening situations or substantial material damage.

Therefore: m Only allow mounting to be performed by employees of the manufacturer or by oth-

er qualified personnel.

1 Switch off the b maXX BM4000 and assure it against unintentional switching on during

mounting.

DANGER!

Risk of fatal injury from electrical current!

There is an immediate risk of fatal injury if live electrical parts are contacted. Therefore:

m Switch off the current when any kind of work is being performed on the electrical

system and ensure safety before switching on again.

m Pay attention to the relevant safety instructions when handling electrical equip-

ment carrying high voltages.

m Do not touch electrically live parts before taking into account the discharge time of

the capacitors

Figure 6: Mounting

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

2 Pull off the design cover towards the front from the controller unit 3 Look at the controller unit for the provided slot

Mounting

4 Turn the twist lock beyond and beneath by 90°.

The twist locks now are standing horizontally.

5 Take the front panel cover towards the front off. Keep this cover.

NOTICE!

Note electrostatic discharge! The BM4-F-AIO-XX contains ESD sensible parts.

Therefore:

m Regard the described ESD procedures when handling the plug-in module. m Touch the plug-in module only at its handle.

6 Take the BM4-F-AIO-XX out of its transport packing. Avoid the contact with electronic

parts of the plug-in module.

7 Plug the BM4-F-AIO-XX module into the guide supports of the slot. The handle must

point to the same side as the other handles in this slot strip (here: right side).

8 Press with two fingers on the front panel until the BM4-F-AIO-XX module within the

device sensible latches tightly into the end position.

9 Turn the twist lock beyond and beneath by 90° into the vertical position (locking posi-

tion).

10 Connect cable of the BM4-F-AIO-XX module with the Sub-D connector. 11 Put the design cover on the device again.

NOTE

If you, within the scope of a repair of the BM4-F-AIO-XX, simply displace it by a similar plug-in module, you can shorten the further operation, installation, commissioning and so on. Then you simply must put on the connector to the plug-in module, put on the design cover again and you can turn on the device again.

Thus the mounting of the BM4-F-AIO-XX is completed.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

6.2

Assembly

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

In this chapter we describe the electrical installation of the AIO-XX or BM4-F-AIO-XX. The mechanical mounting is described in for BM4400, BM4600 and BM4700 with ES controller.

7.1 Safety notes

7INSTALLATION

ZMounting– from page 33 and not necessary

DANGER!

Risk of fatal injury from electrical current!

There is an immediate risk of fatal injury if live electrical parts are contacted. Therefore:

m Switch off the current when any kind of work is being performed on the electrical

system and ensure safety before switching on again.

m Pay attention to the relevant safety instructions when handling electrical equip-

ment carrying high voltages.

m Do not touch electrically live parts before taking into account the discharge time of

the capacitors

WARNING!

Danger because of faulty installation and initial commissioning!

Installation and commissioning require qualified personnel with adequate experience. An installation fault can cause danger situations or large damage of property.

Therefore: m Only personnel from manufacturer or qualified personnel operate while installation

and initial commissioning

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

7.2

Requirements on the electrical connection

7.2 Requirements on the electrical connection

NOTICE!

The danger is: Electricity. In case you do not ensure the requirements to the electrical connection of the Analog IO module, it can be damaged/destroyed.

m Ensure that the electrical power connection parameters as specified in the techni-

cal data are adhered to and that the connections are made in accordance with the instructions.

m Avoid short circuit between input points and output points. In the event of a short

circuit between input points and output points the Analog IO module may get de stroyed.

NOTE!

Pay attention to EMC compatible cabling, see instruction handbook b maXX BM4400, BM4400 ES, BM4600, BM4600 ES, BM4700, BM4700 ES (5.12008), chap ter Installation requirements with regard to EMC.

7.3 Requirements for the connection cables

Following cables are authorized for use by Baumüller: m Copper cable, screened with cross-section of min. 0,25 mm2, screen connected on

both sides

Min. cross section Type of connection

0,25 mm

Sub-D 9-pin female,

metal or metallized

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

7.4 Connection diagrams

Standard controller ES controller

Installation

Figure 7: Connection diagram Analog IO module

Pin assignment Pin No. Assignment

1 IN 1 +

2 IN 2 +

3 OUT 1 - , OUT 2 -

4 OUT 1 +

5 OUT 2 +

6 IN 1 -

7 IN 2 -

8 OUT 1 - , OUT 2 -

Sub-D connector 9-pole

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

9 OUT 1 - , OUT 2 -

Document No.: 5.01045.08

of 82

7.5

Installation procedure

7.5 Installation procedure

1 Switch off the b maXX 4400 device and assure it against unintentional switching on

during mounting.

DANGER!

Risk of fatal injury from electrical current!

There is an immediate risk of fatal injury if live electrical parts are contacted. Therefore:

m Switch off the current when any kind of work is being performed on the electrical

system and ensure safety before switching on again.

m Pay attention to the relevant safety instructions when handling electrical equip-

ment carrying high voltages.

m Do not touch electrically live parts before taking into account the discharge time of

the capacitors

The connection cable of the Analog IO module must be made by the user, refer to ZRe-

quirements for the connection cables– auf Seite 38.

2 Take off the cover from the controller unit (when necessary) 3 Connect the cable with the suitable connector of the Analog IO module (cable goes

downwards)

4 Replace the cover again, if necessary 5 Laying of the cable in the control cabinet, refer to ZRequirements on the electrical con-

nection– auf Seite 38.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

7.6 Internal circuit diagram

7.6.1 Internal circuit diagram of Analog-IO-Modules (BM4-F-)AIO-01/-02/-03

Installation

Figure 8: Internal circuit of Analog IO module (BM4-F-)AIO-01/-02/-03

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

7.6

7.6.2 Internal circuit diagram of Analog IO module (BM4-F-)AIO-04

Internal circuit diagram

Figure 9: Internal circuit diagram of Analog IO module (BM4-F-)AIO-04

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

This commissioning assures, that the Analog IO module has been correctly recognized. Further information relating to commissioning and parameter settings of the encoder module can be found in parameter manual b

Assure that before commissioning the following preconditions are fulfilled:

1 The BM4-F-AIO-XX is correctly mounted (standard controller only). 2 The Analog IO module is correctly mounted at the motor.

3 The switching cabinet is properly closed and all safety devices are put into operation 4 The b maXX 4000 is ready-for-use.

8.1 Safety notes

Basics

8COMMISSIONING/OPERATION

maXX 4000 5.03039.

m The analog IOs must be correctly cabled. m The connection must be suitable to the electrical specification of the Analog IO

module.

WARNING!

Risk of injury due to improper operation!

Improper operation can lead to severe personal injury or material damage. Therefore:

m Perform all operational steps according to the details of these instruction hand-

book.

m Before beginning any work, ensure that all coverings and protective devices are

installed and are functioning properly.

m The control cabinet in which the device is installed should be protected against

contact with electrically live parts. Keep all doors of the control cabinet closed during operation.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

Procedure of the commissioning

NOTICE!

Environmental conditions that do not meet the requirements.

Environmental conditions that are non-compliant can lead to property damage. Therefore:

m Ensure that the environmental conditions are kept compliant during operation (see

instruction handbook b

WARNING!

Risk of injury due to insufficient qualifications!

Inevitably, when operating this electrical device, certain parts of this device are energized with hazardous voltage. Improper handling can lead to significant personal injury and material damage.

Therefore: m Only qualified personnel may work on this device!

maXX 4000, operation conditions).

8.2 Procedure of the commissioning

The test-commissioning is divided into the following sections:

1 Recognition of the Analog IO module. 2 Function test

8.2.1 Recognition of the Analog IO module

While starting, the control unit reads the identification of the Analog IO module automat- ically.

After that, check with the help of ProDrive, whether the Analog IO module has been correctly recognized:

1 Switch on the b maXX BM4000 2 Wait till the system has started

Eliminate any errors / error messages eventually existing in the b maXX BM4000. These errors might have been caused by faulty assembly (e.g. defective cable) or some mistake(s) in installation (e.g. supply voltage absent). Only after having corrected the er rors the commissioning can be continued.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Commissioning/Operation

3 Open with ProDrive the window „Diagnosis“.

Figure 10: ProDrive navigation

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

Procedure of the commissioning

4 Choose submenu „Service“

This window shows the position/slot of the recognized Analog IO module. If the Analog IO module is available in position/slot D, then the following is displayed: „Slot D Analog IO 16 Bit Version X“. „X“ shows the version of the module.

Always available with the ES controller is the module AIO-01 (position E), a further AIO-02/03/04 can be used additionally.

5 Decide on the basis of the display:

of 82

Analog I/O 16 Bit

Analog I/O 8/10 Bit

Figure 11: ProDrive Service

BM4-F-AIO-02

BM4-F-AIO-01

Version B

m If the Analog IO module has been correctly recognized, the commissioning can be

continued, refer to Instruction Handbook b

maXX 4000, 5.12008 or Parameter Man-

ual b maXX 4000, 5.03039.

m If the Analog IO module has not been correctly recognized, turn off the device,

check the mounting and the installation. After removing all errors, switch on the de vice again.

m If the Analog IO module has not been correctly recognized again, it is defect or the

controller/controller slot (of standard controller) is defect. Contact Baumüller Nürn berg GmbH for replacement.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Commissioning/Operation

6 Icon „ProDrive Navigation“

7 Configuration / submenu „IO analog inputs“

Figure 12: ProDrive navigation, submenu „IO analog inputs“

8 The submenu contains „Analog input link 1 and 2“

e.g. choose „Analog input link 1“

The window „Analog input link 1“ is opened. The inputs can be selected in the center of the window.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

Procedure of the commissioning

9 Choose „Input D.1“ in drop down list if the Analog IO module is used in position/slot D.

Figure 13: Analog input link 1

10 Check whether the text: „module not existent“ is displayed directly under the scale.

In this case, the module was not recognized.

Figure 14: Module not existent

m Only if there is no message under the scale, the AIO-XX or BM4-F-AIO-XX is rec-

ognized properly and can be used.

m If the AIO-XX or BM4-F-AIO-XX is not recognized, then switch off the device and

check the assembly/installation. After having removed all errors, restart the device for checking whether the plug-in module gets recognized properly now.

m If the Analog IO module is not recognized yet, then it is defective or the controller/

controller slot. In that case, contact Baumüller Nürnberg GmbH for replacement.

m Once the Analog IO module has been recognized properly following with

ZTesting of the Analog IO module– from page 49.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

NOTICE!

Notice electrostatic discharge The BM4-F-AIO-XX or the b maXX BM4000 may get damaged if the module is

plugged or pulled out when the b If the plug-in module has still to be pulled out from the b maXX BM4000 due to an

external action, switch off the b Try then to push in the Analog IO module again as described in the chapter ZMount-

ing– from page 33 and ZInstallation– from page 37.

Restart the b maXX BM4000 again and check for errors/error messages.

8.2.2 Testing of the Analog IO module

Once the plug-in module has been recognized properly, then it can be checked whether the input and outputs are working correctly using ProDrive.

Commissioning/Operation

maXX BM4000 is energized.

maXX BM4000.

Pre-conditions Basic unit b maXX BM4000 has been commissioned,

BM4-F-AIO-XX has been plugged in or AIO-XX is available (ES controller).

Analog connections are available/connected and ready for use (pin assignment see

ZConnection diagrams– on page 39), in addition:

m AIO-01, AIO-02, AIO-03

Voltage range of +/-10 VDC can be set by a potentiometer.

m AIO-04

Current range of 0 ... 20 mA can be set by a current calibrator

Motor for speed set (clockwise or counter-clockwise) has been connected; shaft ends are rotating freely.

h ProDrive Navigation „Diagnosis“, submenu „Service“. h Check in the menu „Service“, whether the Analog-IO-Module has been correctly rec-

ognized, e.g. in the line for the slot D

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

8.2.2.1 Testing of inputs AIO-01, -02 and -03

Procedure of the commissioning

1 ProDrive Navigation „IO analog inputs“. 2 Select „Analog input link 1“ in ProDrive.

Figure 15: Analog input link 1, AIO-01, -02 and -03

3 By clicking on the g-symbol, select the entry „Input D.1“ („D“ ⇒ module in position D,

„1“ ⇒ input 1) from the drop-down list.

Figure 16: Input selection AIO-01, -02 and -03

4 Enter in menu „analog input link 1“:

m Target parameter number: „1171“, (ramp function generator input) m Smoothing time: „10 ms“, m Scaling factor: „1“, m Offset: „0“, m Threshold: „0“,

of 82

A scale is displayed and shows the applied voltage (set by the potentiometer), e. g. +10 V.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Commissioning/Operation

5 Check the display in „Analog input link 1“.

The RPM of the motor can be regulated now by potentiometer for instance within limits

-10 V and +10 V (clockwise and counter-clockwise running).

NOTE!

If for example, the scale shows 0 V, even though there is an analog voltage applied on input 1 (see pin assignment is defective. When changing the analog input voltage, the relevant value of the voltage must be displayed on the scale.

6 Repeat the above steps for the input 2.

ZConnection diagrams– on page 39), then the input

8.2.2.2 Testing of inputs AIO-04

1 ProDrive Navigation „IO analog inputs“. 2 Select „Analog input link 1“ in ProDrive.

Figure 17: Analog input link 1, AIO-04

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

Procedure of the commissioning

3 By clicking on the g-symbol, select the entry „Input E.1“ („E“ ⇒ module in position E,

„1“ ⇒ input 1) from the drop-down list

Figure 18: Input selection AIO-04

4 Enter in menu „Analog input link 1“ :

m Target parameter number: „1171“, (ramp function generator input) m Smoothing time: „10 ms“, m Scaling factor: „1“, m Offset: „0“, m Threshold: „0“,

A scale is displayed and shows the applied current (set by the current calibrator), e. g. +12

mA.

5 Check the display in „Analog input link 1“. The RPM of the motor can be regulated now by the current calibrator.

NOTE!

If for example, the scale shows 0 mA, even though there is a current applied on input 1 (see pin assignment tive. When changing the applied current, the relevant value of the current must be displayed on the scale.

6 Repeat the above steps for the input 2.

ZConnection diagrams– on page 39), then the input is defec-

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

8.2.2.3 Testing of outputs

Note the ZPre-conditions– on page 49.

1 Select in ProDrive „IO analog outputs“

Commissioning/Operation

Figure 19: Analog output link

2 Select submenu „Analog output link 1“.

Figure 20: Menu Analog output link 1

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

Procedure of the commissioning

3 By clicking on the g-symbol, select the entry „Output D.1“ („D“ ⇒ Analog IO module

in position D, „1“ ⇒ output 1) from the drop-down list.

Figure 21: Output selection

4 Enter in menu Analog output link 1:

m Source parameter: „1171“, m Offset: „0 dig“, m Shift factor: „0“, m Scaling factor: „1638 Dig/V“.

The voltage at the output point D.1 (see pin-assignment, ZConnection diagrams– on page 39) can be measured now by using the suitable measuring instrument. If +10 V has been applied at the input D.1, then there will also be an output voltage of +10 V at the analog output.

NOTE!

If no voltage can be measured at the output 1 (see pin assignment ZConnection di-

agrams– on page 39), even though the voltage is changed at the input 1, then either

the Analog-IO-Module or the controller/controller unit is defective.

5 Repeat the test for output 2 With that, testing of the Analog-IO-Module is complete.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Commissioning/Operation

8.2.3 Offset adjustment of an analog input channel

Pre-conditions Basic unit b maXX BM4000 commissioning completed,

Analog IO module available.

8.2.3.1 Offset adjustment of AIO-01, -02, -03

Required accessory

n Voltmeter n Voltage source (e.g. 9V monobloc battery)

with Sub-D connector (9 pin) for analog inputs 1 and 2 and connection for the voltmeter

n Sub-D connector (9 pin) with inputs 1 and 2 short-circuited

(Pin assignment see ZConnection diagrams– on page 39)

n Computer with ProDrive

NOTE!

All settings must be done when controller state is disabled.

Offset adjustment within the analog input link

Set 16 Bit application parameter as target for the analog input link. Example: Target parameter = P3333

Read the value in ProDrive while input is short-circuited. Example: -179 increments

Offset adjustment:

Example offset adjustment =

read value 100–()⋅

---------------------------------------------------32767

179– 100–()⋅

----------------------------------- 0546,= 32767

⇒ value to be set: 0,55 %.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.2

Procedure of the commissioning

Gain adjustment within the analog input link

Connection and measurement of a reference voltage (e.g. 9V monobloc battery) Measured voltage (voltmeter): 9,235 V Read value in ProDrive: 29295 Conversion of read value into voltage: =

read value 10 V⋅

---------------------------------------------32767

29295 10 V⋅

----------------------------------- 8940 V,= 32767

Gain to be set =

connected (measured) voltage

----------------------------------------------------------------------------------

read voltage

9235 V,

--------------------- - 1033,== 8940 V,

= 1,03

Check

Input short-circuited ⇒ No. of increments < 20

Connect voltage supply Convert connected voltage to increments:

No. of increments =

32767 connected (measured) voltage⋅

----------------------------------------------------------------------------------------------------- -

10 V

32767 9 235 V,⋅

------------------------------------------- 30260== 10 V

The adjustment of an analog input channel of the AIO-01, AIO-02 and AIO-03 is completed now.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

8.2.3.2 Offset adjustment AIO-04

Commissioning/Operation

Required accessory

n Current calibrator n Computer with ProDrive n Amperemeter

NOTE!

All settings must be done when controller state is disabled.

Offset adjustment within the analog input link

Set 16 Bit application parameter as target for the analog input link. Example: Target parameter = P3333

Read the value in ProDrive while input is open (0 mA). Example: -179 increments

Offset adjustment:

Example offset adjustment =

read value 100–()⋅

---------------------------------------------------65534

179– 100–()⋅

----------------------------------- 0.273= 65534

⇒ value to be set: 0.273 %.

Gain adjustment within the analog input link

Connection 10 mA Measured current (amperemeter): 10.000 mA Read value in ProDrive: 32900 Conversion of read value into current: =

Gain to be set =

connected (measured) voltage

----------------------------------------------------------------------------------

read value 20 mA⋅

-------------------------------------------------65534

32900 20 mA⋅

---------------------------------------- 10.041 mA=

65534

read voltage

9235 V,

--------------------- - 0.996== 8940 V,

= 0,996

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.3

Operation

8.3 Operation

Setting of parameters determines the reaction of the Analog IO module during operation. These parameters are set by the software ProDrive.

The procedure for “Analog input Link 1” is described below via an example. The procedure for “Analog output Link 2” and the analog outputs is similar.

1 Start ProDrive 2 Click „ProDrive Navigation“ 3 Click on + „IO analog inputs“

(path: Device/configuration/IO analog inputs)

of 82

Abbildung 22: ProDrive Navigation

4 Click on „Analog input link 1“ 5 Now open the menu „Analog input 1“ with the data for one of the analog inputs.

In the icon bar the parameter list button l can be found.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Commissioning/Operation

6 Click on l for opening the parameter list. 7 Click on the + -symbol before „Configuration IO analog“ in the window „Parameter-

list“. The corresponding parameters of the Analog IO module are displayed.

Figure 23: Configuration, parameter list

NOTE!

The error parameters of the Analog-IO-Modules can be found in the chapter ZError

messages– from page 69.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

8.3

Operation

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

9.1 Safety notes

Basic information

WARNING!

Risk of injury due to improperly performed maintenance work!

Improper maintenance can lead to severe personal injury and material damage. Therefore:

m Before beginning work, make sure that there is enough space for mounting. m Make sure that the mounting area is kept clean and orderly. Parts and tools that

are loosely stacked or lying around are a potential accident source.

9.2 Environmental condition

9MAINTENANCE

If the prescribed environmental conditions are adhered to, then the device is maintenance-free. For the prescribed environmental conditions see Instruction handbook

maXX BM4000.

The most important prescribed environmental conditions are:

m Dust-free environmental air m Temperature: Min. 5 °C to max. +55 °C m Relative humidity: 5% to 85%, no condensation m Installation altitude: From 1000 m and higher derating

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

9.3

Inspection intervals - maintenance notes

9.3 Inspection intervals - maintenance notes

Refer to Instruction handbook b maXX 4000, 5.12008.

9.4 Repairs

In case of device damage, please inform your sales office or:

Baumüller Nürnberg GmbH

Ostendstr. 80 - 90 90482 Nuremberg Germany

Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30

Mail: mail@baumueller.de Internet: www.baumueller.de

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

10.1 Behavior in case of malfunctions

Basic information

DANGER!

Risk of fatal injury from electrical current!

Inevitably, when operating this electrical device, certain parts of it are energized with hazardous voltage.

Therefore: m Pay heed to areas on the device that could be dangerous.

10TROUBLESHOOTING AND

FAULT CORRECTION

WARNING!

Risk of injury due to improper fault correction!

Therefore:

m Only qualified personnel may work on this device! m Personnel that work with the b maXX device must be trained in the safety regula-

tions and the handling of the device, and be familiar with the correct operation of it. In particular, reacting to error indications and conditions requires that the oper ator must have special knowledge.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

10.2

Fault detection

10.2 Fault detection

The fault can be caused by mechanical or electrical malfunctions.

LED H4 The occurrence of an error state of a device b maXX 4000 is signalled by the lighting up

of the red LED H4 on the front side of the housing.

NOTE!

If warnings or errors occur without error reaction the LED H4 „error“ flashes. Only error messages with error reaction are displayed by constantly lighting up.

7-segment display Additionally the error code is shown via the 7-segment display on the front side of the

housing (not BM4XXX - XXX - XX0XX and BM4XXX - XXX - XX1XX). By the displayed code the error message can be determined. The displayed error is with-

out exception an LEVEL 2 error (P0201 - P0216). The display of an error code starts by displaying „F“ for 1.5 s. Then the four characters of

the error code are displayed. The separate characters are displayed for about 0.8 s, in terrupted by a short break. If there are other errors, these are displayed in the same manner. The procedure is repeated as soon as all errors were displayed.

Example: Error 125 and 91 are generated:

Start End Time Error code display

Figure 24: Error messages 7-segment display

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Troubleshooting and Fault correction

Operating software ProDrive

Furthermore the error message is shown in the operating software: h Start the operating program ProDrive (from FW 3.07), if it isn’t running yet.

NOTE!

The controller software version and the operating software version must be compatible to use ProDrive with all functions.

Display the „error message“ in ProDrive:

h Open navigation with click on + in front of „Management“

Figure 25: ProDrive navigation

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

10.2

Fault detection

h Select „Drive management“ The window „Drive manager“ opens, see below with an exemplary (error) message.

Before the communication between controller and PC/laptop is started, the messages in this list have been arranged in numerical order. The newly occurring messages are added to the end of the list, when communication is active.

of 82

Figure 26: Drive manager ProDrive

NOTE

If you are not able to start the motor, although the red LED H4 is not lighting up and although the LED H2 is lighting up green, check the parameterization of the

maXX 4000 with the parameter list in ProDrive.

Error possibilities are e. g.: torque limit = 0 has been set or notch position is not correct (also see parameter manual b maXX 4000).

If no LEDs are lighting up on the front side of the device, check the 24V supply.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Troubleshooting and Fault correction

10.3 Error handling

The error messages in the system are built up hierarchically. An error message can result from a beneath in the hierarchic arranged error message.

This is why the message „Error“ (level 1) can base on an error, which e. g. has appeared in „ModuleError“ (level 2), because there is a failure in „Function module1“ (level 3, e. g. sine cosine encoder module).

Error memory From firmware V03.11 onwards an internal error memory exists to read out errors by a

higher-level open-loop control. All occurring errors which lead to an error response of the drive are saved chronologically in this error memory.

A read access to the error memory is done element by element with an index parameter (P0258) and a value parameter (P0259).

The error memory will be deleted completely at error acknowledgment (Bit 7 = 1 in control word).

For a further description see parameter P0257 in the Parameter Manual.

Error display If an error appears, the according definite error message is displayed within a short time

in ProDrive in the menu „Device manager’ and on the 7-segment display.

NOTE!

The device is provided with predefined error reactions. You are able to set the error reaction of the device in „Depending on settings“ in the column „Reaction“ marked er ror messages. An exception are errors, which have to have an immediate pulse inhibit as a consequence. These can not be changed due to safety reasons.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

10.3

10.3.1 Error reset

Error handling

If the red error LED is lighting up, there is at least one error. There are several methods to reset errors:

m Via ProDrive (from FW 3.07):

Button “Quit errors” (either in the dialog box “Device manager” or on the page “Device manager“. That means, you inform the device, that you have noted the error, that you have removed it or that you want to pass over it. Due to error reset all error messages are reset. An individual error reset is not possible. The button „Quit errors“ causes a resetting of the error, in case the cause for the error message exists no longer.

Figure 27: ProDrive Drive manager

m Via writing access to control word (P0300):

Here a rising edge must be generated in bit 7 (generated by the control system or by operating software via input to parameter list). Note: The drive control must be active (see parameter P1001 „Communication source“) for the selected communication source.

m Via a digital input:

A digital input of a DIO module can be selected via parameter P0575 „Digital input for error acknowledgement“ for error reset. A rising edge on this input resets the error messages.

m Via the pulse enable input:

Precondition is, that the drive is only controlled via the hardware inputs (that means that the motor guide is neither set via the operating software nor via another commu nication source). Furthermore the option “Quit error via pulse enable” in parameter P1002 „Options device manager“ must be active. With the first rising edge of pulse en able the errors then are reset. But the drive still does not start. Therefore you then need a second rising edge for the enable.

Additional data according the subject resetting of error messages is available in the „Parameter manual“.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

10.3.2 Error messages

Troubleshooting and Fault correction

Figure 28: Survey error list

The (error) messages are displayed in ProDrive window „Drive manager“.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

10.3

Error handling

1st level 1st level errors are only interesting for the access to errors via parameters, to be used

without ProDrive, e. g. at Field bus communication. These errors are not shown in Pro Drive/7-segment display.

Bit mapping see description of the parameter P0200 in the parameter manual.

2nd level 3rd level

Order of the error messages see survey (ZAbbildung 28– auf Seite 69). 2nd level error messages are displayed on the 7-segment display in ProDrive.

In the column „Reaction“ the reaction of the system to the error is shown:

m „pulse stop“ = inhibit pulses m „adjustable“ = the error reaction can be set via ProDrive (Window „Drive management“,

toolbar button „Error reaction“).

m „no reaction“ means, the drive is continuing to work and the red error LED is blinking.

2nd level error messages

P0204 Error in function or option modules

Error No. Meaning Reaction Troubleshooting

48 Error in function module A 3rd level

49 Error in function module B

50 Error in function module C

51 Error in function module D

52 Error in function module E

error

see

ZError in function module A to E– on page 71 (= 3rd

level)

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Troubleshooting and Fault correction

3rd level error messages

NOTE!

3rd level errors are only displayed in ProDrive separated by a decimal point from the corresponding 2nd level error (refer to

e.g.: Motor error 102: Group error find notch position (2nd level)

Find notch position error 102.64: Drive moved more than 4 times delta angle.

P0240 to P0244 Error in function module A to E

Error No. Meaning Reaction Troubleshooting

0 reserved error

1 Module not identified no

2 Identified module is not permitted at this posi-

tion

3 Digital output short-circuited or 24V supply not

connected to the DIO module

4 Invalid target parameter value caused by digital

input

5 Direct PLC-IO access for this module not per-

mitted

6 Required module is missing, only for BM4100

active mains rectifier unit

7 Module must not be used for actual active

mains rectifier unit mode or controller mode

8 Reserved no

9 Too much Analog-IO-Modules connected no

10 AIO-04: current < 4 mA no

11 AIO-04: current > 20 mA no

ZAbbildung 28– auf Seite 69).

Check if the right module is plugged at the right posi-

reaction

Pulse

stop

reaction

tion

Check the cabling of the digital outputs

Check the parameterization of the input channel

Don’t select the module

Connect the required module for operation with active mains rectifier - see operation handbook b BM4100 active mains rectifier unit

More than 2 analog modules are not allowed

Current source not connected, disconnection or shortcircuit

Current source impress too much current

(3rd level)

maXX

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

10.3

Error handling

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

11.1 Safety notes

11DISPOSAL

NOTE!

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

DANGER!

Risk of fatal injury from electrical current!

Stored electric charge. Discharge time of the system = discharge time of the device with the longest DC link

discharge time in the DC link connection. Refer to Instruction handbook b maXX BM4000, Electrical data.

Therefore: m Do not touch before taking into account the discharge time of the capacitors and

electrically live parts.

m Heed corresponding notes on the equipment. m If additional capacitors are connected to the DC link, the DC link discharge can

take a much longer time. In this case, the necessary waiting period must be deter mined or a measurement made as to whether the equipment is de-energized. This discharge time must be posted, together with an IEC 60417-5036 (2002-10) warn ing symbol, on a clearly visible location of the control cabinet.

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

11.2

Disposal facilities/authorities

NOTICE!

Avoid polluting the environment as a result of improper disposal.

Therefore:

m Only dispose in compliance with the health and safety regulations. m Take heed of any special local regulations. If you are unable to directly ensure safe

disposal yourself, commission a suitable disposal contractor.

m In the event of a fire, hazardous substances could possibly be generated or re-

leased.

m Do not expose electronic components to high temperatures. m Beryllium oxide is used as inner insulation, for example for various power semicon-

ductors. The beryllium dust that is generated upon opening is injurious to the health. Do not open electronic components.

m Dispose of capacitors, semiconductor modules and electronic scrap as special

waste.

WARNING!

Danger as a result of faulty deinstallation!

The deinstallation and disposal requires qualified personnel with adequate experience.

Therefore: m Only allow deinstallation and disposal to be performed by qualified personnel.

11.2 Disposal facilities/authorities

Ensure that the disposal is handled in compliance with the disposal policies of your company, as well as with all national regulations of the responsible disposal facilities and authorities. In case of doubt, consult the bureau of commerce or environmental protection authority responsible for your company.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

APPENDIX A - DECLARATION OF

CONFORMITY

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

EG - Declaration of Conformity Doc.-No: 5.12050.00

Date: 25-Sep-2012

according to EMC Directive 2004/108/EC and Low Voltage Directive 2006/95/EC

The Manufacturer: Baumüller Nürnberg GmbH

Ostendstraße 80-90

90482 Nuremberg, Deutschland declares that the product: Name: b maXX

Type: Analog IO module b maXX BM4000

BM4-F-AIO-01, BM4-F-AIO-02, BM4-F-AIO-03, BM4-F-AIO-04

From manufacturing date: 1-Oct-2012

as developed, designed and manufactured in accordance with the EMC Directive 2004/108/EC and the Low Voltage Directive 2006/95/EC.

Applied harmonized standards:

Standard Title

DIN EN 62061:2010-05 Safety of Machinery - Functional safety of safety-related electrical, electronic and programmable

DIN EN 61800-5-1:2008-04 Variable-speed electrical power drives-

DIN EN 61800-5-2:2008-04 Variable-speed electrical power drives

DIN EN 61800-3:2005-07 Variable-speed electrical power drives

electronic control systems

Part 5-1: Safety requirements - Electrical, thermal and energy

Part 5-2 Safety requirements - Functional

Part 3: EMC-requirements and specific test methods

The listed devices cannot be operated without a basic controller unit. The compliance to the guidelines require a correct assembly of the products and the careful attention of the associated instruction handbooks of BM4000 and of BM4-F-AIO-XX Analog-IO-Module.

The compliance to the above mentioned guidelines are checked on the basis of typical BM4000 controller configurations.

Nürnberg / 25-Sep-2012

Place / Date

The content of the Declaration of Conformity is subject to change. The current version can be obtained on request.

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Table of figures

b maXX BM4000) ...................................................................................................................... 21

Analog IO module for standard controller .................................................................................. 23

Type plate BM4-F-AIO-XX for standard controller..................................................................... 25

AIO-XX for ES controller ............................................................................................................ 27

BM4-F-AIO-XX for standard controller ....................................................................................... 33

Mounting .................................................................................................................................... 34

Connection diagram Analog IO module ..................................................................................... 39

Internal circuit of Analog IO module (BM4-F-)AIO-01/-02/-03.................................................... 41

Internal circuit diagram of Analog IO module (BM4-F-)AIO-04 .................................................. 42

ProDrive navigation.................................................................................................................... 45

ProDrive Service ........................................................................................................................ 46

ProDrive navigation, submenu „IO analog inputs“ ..................................................................... 47

Analog input link 1...................................................................................................................... 48

Module not existent .................................................................................................................... 48

Analog input link 1, AIO-01, -02 and -03 .................................................................................... 50

Input selection AIO-01, -02 and -03 ........................................................................................... 50

Analog input link 1, AIO-04 ........................................................................................................ 51

Input selection AIO-04................................................................................................................ 52

Analog output link....................................................................................................................... 53

Menu Analog output link 1.......................................................................................................... 53

Output selection ......................................................................................................................... 54

ProDrive Navigation ................................................................................................................... 58

Configuration, parameter list ...................................................................................................... 59

Error messages 7-segment display............................................................................................ 64

ProDrive navigation.................................................................................................................... 65

Drive manager ProDrive............................................................................................................. 66

ProDrive Drive manager............................................................................................................. 68

Survey error list.......................................................................................................................... 69

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

Table of figures

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Index

Accidents 16 Assembly 34

Caution 6 Connecting cables, requirements 38 Customer service 8

Danger 6 Danger areas 26 DC link discharge time 14, 73 Design cover 34 Diagnosis 45 Discharge, electrostatic 35 Disposal 8, 73 Drive management 66

Electrical connection, requirements 38 Electrical current, dangers of 14 Error handling 67 Error messages 69 Error reset 68 ES controller 21

Fault correction 63 Fault detection 64 Fire fighting 15 Function modules 23

Guarantee provisions 8

Hazardous situations 16 Hazards, special 14

Initial commissioning 37 Inspection 62 Inspection intervals 62 Installation 37 Installation, procedure 40 Internal circuit diagram 41, 42

Key to symbols 6

LED H2 66 LED H4 66 Limitation of liability 7

Maintenance 61 Malfunctions, behavior 63 Modifications 11

Note 6

Operating instructions, contents 11 Operating personnel 13 Operation 43 Option modules 23

Packaging, disposal of 32 Parameter list 66 Parameterization 66 Personnel, qualified 13 Personnel, training 13 Pin assignment 39 Procedure of commissioning 44 ProDrive 49, 58, 66

Recognition of Analog IO module 44 Repairs 62 Residual energy, danger from 14

Safety equipment 16 Scale 48 Spare parts 8 Standard controller 21

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

Index

Technical data 19 Temperature range 20 Testing of inputs 50, 51 Transport inspection 31 Troubleshooting 63 Twist lock 35 Type code

ES controller 29

Standard controller 26 Type of plug-in module 26 Type plate

ES controller 29

Standard controller 25

Unpacking 32 Use, compliant with indented purpose 12

Warning 6 Warning notes 6

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

Revisionsübersicht

Overview of Revisions

Version Status Changes

5.01045.06 25.09.2012 Revision because of AIO-04, new design

5.01045.07 13.03.2014 Revision ES controller, troubleshooting

5.01045.08 12.12.2014 Troubleshooting

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module)

Document No.: 5.01045.08

of 82

Notes

of 82

Instruction handbook b maXX (BM4-F-)AIO-XX (Analog IO module) Document No.: 5.01045.08 Baumüller Nürnberg GmbH

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. Before you make any information given in this manual to the basis of your own calculations and/or applications, please make sure that you have the latest edition of the information in hand. No liability can be accepted concerning the correctness of the information.

Baumuller BM4-F-AIO-01, BM4-F-AIO-02, BM4-F-AIO-03, BM4-F-AIO-04 Instruction Handbook Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1.1 Information on this Instruction handbook

1.2 Key to symbols

1.3 Limitation of liability

1.4 Copyright protection

1.5 Other applicable documents

1.6 Spare parts

1.7 Disposal

1.8 Guarantee provisions

1.9 Customer service

1.10 Used terms

1.11 List of associated documentations

2.1 Contents of the Instruction Handbook

2.2 Changes and modifications to the device

2.3 Use, compliant with intended purpose

2.4 Responsibility of the operating company

2.5 Training of the personnel

2.6 Special hazards

2.7 Fire fighting

2.8 Safety equipment

2.9 Behavior in hazardous situations or at accidents

2.10 Signs and labels

3.1 Electrical data

3.2 Power input

3.3 Input linearity error

3.4 Operation conditions

4.1 Function

4.2 BM-F-AIO-XX for standard controller

4.2.1 Slots BM4-F-AIO-XX for standard controller

4.2.2 Type plate BM4-F-AIO-XX for standard controller

4.2.3 Type code BM4-F-AIO-XX for standard controller

4.2.4 Danger areas BM4-F-AIO-XX for standard controller

4.3 AIO-XX in ES controller

4.3.1 Position AIO-XX in ES controller

4.3.2 Type plate AIO-XX in ES controller

4.3.3 Type code AIO-XX in ES controller

4.4 Display and operation elements

5.1 What to observe when transporting

5.2 Transport inspection

5.3 Unpacking

5.4 Disposal of the packaging

6.1 Preparation of mounting

6.2 Assembly

7.1 Safety notes

7.2 Requirements on the electrical connection

7.3 Requirements for the connection cables

7.4 Connection diagrams

7.5 Installation procedure

7.6 Internal circuit diagram

7.6.1 Internal circuit diagram of Analog-IO-Modules (BM4-F-)AIO-01/-02/-03

7.6.2 Internal circuit diagram of Analog IO module (BM4-F-)AIO-04

8.1 Safety notes

8.2 Procedure of the commissioning

8.2.1 Recognition of the Analog IO module

8.2.2 Testing of the Analog IO module

8.2.2.1 Testing of inputs AIO-01, -02 and -03

8.2.2.2 Testing of inputs AIO-04

8.2.2.3 Testing of outputs

8.2.3 Offset adjustment of an analog input channel

8.2.3.1 Offset adjustment of AIO-01, -02, -03

8.2.3.2 Offset adjustment AIO-04

8.3 Operation

9.1 Safety notes

9.2 Environmental condition

9.3 Inspection intervals - maintenance notes

9.4 Repairs

10.1 Behavior in case of malfunctions

10.2 Fault detection

10.3 Error handling

10.3.1 Error reset

10.3.2 Error messages

11.1 Safety notes

11.2 Disposal facilities/authorities

Table of figures

Index

Overview of Revisions