Instruction handbook
Language English
Translation
Document No. 5.16027.04
Part No. 464136
Edition 22-May-2019
E
5.16027.04
b maXX 5000
BM5800
Multi-axis controller
Read the Instruction handbook before starting any work!
Copyright This Instruction handbook may be copied by the owner in any quantity, but only for internal
use. This Instruction handbook may not be copied or reproduced, in whole or in part, for any
other purposes.
The use and disclosure of information contained in this Instruction handbook are not 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 another location, these 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 are 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 these 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
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Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information on the instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 List of other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Contents of the Instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Usage for the intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Risk assessment according EU Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.12 Conduct in case of danger or accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.13 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.1 BM5807-S dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2 BM5807-A dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.1 Requirements for control voltage / 24 V power supply . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.2 Requirements for the motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.4 Correction values at changed operation conditions . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.4.1 Correction values for the output current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.4.2 Correction values DC link voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3.5 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.1 Double axis modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.2 Single axis modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.3 Output frequency-dependent current derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.4 Load cycle according EN61800-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Identification of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.1 Part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.3 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3 UL notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 Display and operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4.1 Minimum configuration BM58XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4.2 Maximum configuration BM58XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4.2.1 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4.2.2 Option: LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4.2.3 Option: 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.4.3 LED display fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3 Transport inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Preparing for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2.1 Drilling pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3.1 Mounting with mounting rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.3.2 Mounting without mounting rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.3.3 Mounting of the DC link bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2 Voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.3 Demands on the electrical mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.4 Requirements for the connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.5 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.6 Grounding concept of MAR and side-by-side mounted system . . . . . . . . . . . . . . . . . . 76
7.7 Installation requirements with regard to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.8 Shielding plan side-by-side mounted system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.8.1 Shielding connection mounting plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.8.2 Shielding connection with shield sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.8.2.1 Mounting shield sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.8.2.2 Connecting the shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.9 Requirements for the motor temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.10 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.11 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.11.1 Connection diagram overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.11.2 Connection diagram axis module -1 / -2 / -3 (single axis module). . . . . . . . . . . . . . . 87
7.11.3 Connection diagram axis module -1 / -2 / -3 (double axis module) . . . . . . . . . . . . . . 88
7.11.4 Connections BM5800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.11.5 Connection data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.11.6 Option: STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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7.11.7 Fast digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.11.8 Encoder evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.11.9 Motor temperature and motor brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.11.10 Option: Additional fast digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.11.11 Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.11.12 Option: Analog outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.1 STO function option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.1.1 Safety notes according function STO (Safe Torque Off) . . . . . . . . . . . . . . . . . . . . . 110
8.1.2 Safety levels and safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.1.3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.1.4 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.1.5 Examples for input wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.3 Fieldbus communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.3.1 EtherCAT® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.3.2 VARAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8.3.3 CANopen® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.3.4 POWERLINK® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9.1 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.2 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10 Troubleshooting and Fault correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.2 Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.3 Error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.4 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
11 Accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.1 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.1.1 Device - mains cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.1.2 Hybrid cable device-encoder-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.1.3 Control voltage supply/signal cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11.1.4 EtherCAT®, VARAN, POWERLINK® cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11.1.5 Accessories - CANopen® .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
11.1.6 Encoder cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
11.1.6.1 Connecting cable for Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
11.1.6.2 Connecting cable for encoder with HIPERFACE® . . . . . . . . . . . . . . . . . . . . . . . . . 147
11.1.6.3 Connecting cable for encoder with EnDat® or SSI . . . . . . . . . . . . . . . . . . . . . . . . . 148
11.1.6.4 Connecting cable for encoder with EnDat® 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.1.6.5 Connecting cable for sine/square-wave incremental encoder . . . . . . . . . . . . . . . . 151
11.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11.2.1 Plug connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11.2.2 Accessories kit shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
11.3 Connection rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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Table of Contents
12 Shutdown, Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
12.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
12.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
12.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
13 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Appendix A - Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Appendix B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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1.1 Information on the instruction handbook
These instruction handbook provides important information on handling the device. A prerequisite for safe work is compliance with all specified safety notes and procedural instructions.
Additionally, the valid accident prevention regulations and general safety regulations applicable to the scope of application the device must be complied with.
Read the instruction handbook, particularly the safety notes chapter, completely before
beginning any work on the device. The instruction handbook is part of the product and
must be kept accessible to personnel at all times in the immediate vicinity of the device.
1.2 Key to symbols
Warning notes
Warning notes are identified by symbols in these 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.
1GENERAL
DANGER!
....points out an immediately dangerous situation that will lead to severe injuries or
death if not avoided.
WARNING!
....points out a potentially dangerous situation that could lead to severe injuries or
death if not avoided.
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7
1.3
Recommendations
Limitation of liability
CAUTION!
....points out a potentially dangerous situation that could lead to minor or slight inju-
ries if not avoided.
NOTICE!
....points out a potentially dangerous situation that could lead to material damage if
not avoided.
NOTE!
....highlights useful tips and recommendations, as well as information for efficient and
problem-free use.
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 non-compliance 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.
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1.4 Copyright protection
General
1
The instruction handbook must be treated confidentia
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!
he specific contents, text, drawings, images and other representations are copy-
T
righted and subject to industrial property rights. Any prohibited usage is punishable
by law.
CANopen
EnDat
EtherCAT
HIPERFACE
HIPERFACE DSL
PROFINET
speedtec
®
®
®
®
is a registered trademark of PROFIBUS International
®
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
is a registered trademark of INTERCONTEC GmbH
94559 Niederwinkling, Germany
lly. It is to be used exclusively by
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.
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 regulations has been declared for the components by the respective manufacturers.
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1.6
Spare parts
1.6 Spare parts
1.7 Disposal
WARNING!
lse or flawed spare parts can lead to damage, malfunction or complete fail-
Fa
ure, thus endangering safety.
Therefore:
m Only use original spare parts of the manufacturer.
Procure spare parts through an authorized dealer or directly from the manufacturer.
Refer to ZAccessories and spare parts– from page 135.
Insofar as no take-back or disposal agreement has been made, please disassemble units
correctly and properly recycle the constituent parts.
Refer to ZDisposal– on page 159.
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 operation 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 these instruction handbook, then all guarantee and warranty rights are
rendered null and void.
1.9 Customer service
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.
1.10 Terms used
The term „device“ or the item designation BM58XX are also used in this documentation
for the Baumüller product „b maXX 5800“. A list of the abbreviations used can be found
in ZAppendix A - Abbreviations– from page 163.
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1.11 List of other applicable documents
General
1
Instruction
handbook
Parameter manual
Instruction
handbook safety
modules
Instruction
handbook add-on
modules
Doc.-No. Part No.
Instruction handbook b maXX 5000, 5100, 5300 5.09021 439682 439682
Instruction handbook b maXX 5500, 5600, 5700 5.13008 446683 446684
Instruction handbook b maXX 5800 5.16027 464134 464136
Doc.-No. Part No.
Parameter manual b maXX 5000 5.09022 428331 431082
Parameter manual b maXX 5800 5.16029 470715 470716
Doc.-No. Part No.
Safety modules for b maXX 5000 BM5-O-SAF-000/-001 5.09013 428339 432449
Safety modules for b maXX 5000 BM5-O-SAF-002/-003 5.01046 354843 372666
Doc.-No. Part No.
Add-on module IEE / SIE 5.13030 448189 448190
German
German
German
German
Part No.
English
Part No.
English
Part No.
English
Part No.
English
Application
handbooks
Doc.-No. Part No.
German
CANopen, CoE, POWERLINK for b maXX 2500/3000/5000 5.14006 450924 450925
SoE-Slave for b maXX 2500/3000/5000 5.14010 452983 452984
PROFINET IRT device for b maXX 2500/3000/5000 5.15009 456326 456327
Servo pump function V1 for b maXX 5000 5.17002 - 466346
Part No.
English
Instruction handbook b maXX 5800
Document No. 5.16027.04
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1.11
List of other applicable documents
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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 the instruction handbook before working with the device. This also applies if the person 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
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2.3
Usage for the intended purpose
2.3 Usage for the intended purpose
The device is conceived and constructed exclusively for usage compliant with its intended
purpose described in these instruction handbook.
The devices of the model series b maXX 5000 are either mains rectifier or active mains
rectifier in combination with axis units or multi-axis controllers or decentralized drive solutions. Devices are also available in graduated design size and performance classes.
The multi-axis controller b maXX 5800 is connected to mains rectifier or active mains rectifier of b maXX 5000. The integrated axis modules are used for controlling motors.
A device is considered as being used compliant with its intended purpose if all notes and
information of these instruction handbook 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 device compliant with its intended purpose.
m Observe all specifications of these instruction handbook.
m Ensure that only qualified personnel work with/on this device.
m When configuring, ensure that the device is always operated within its specifica-
tions.
m Mount the device on a wall that can sufficiently bear the load.
m The device must always be operated within a control cabinet.
m Ensure that the power supply complies with the stipulated specifications.
m The device may only be operated in a technically flawless condition.
m Only operate the device in combination with components approved by Baumüller
Nürnberg GmbH.
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2.4 Risk assessment according EU Directive
Earth current Check the quality of the earth connection:
- before connecting the device to the power supply for the first time and
- within the recommended service intervals
Requirements:
m Cross section of the grounding cable according EN 61800-5-1
m Note the required torque of connection!
m Grounded mounting plate made of metal
m Mains filter, device and shielding of the motor cable are on the same HF potential
Safety
2
Stored
electric charge
Electromagnetic
fields
Burn injuries Please note that the surface of the device can heat up considerably.
Radiated emission The high-frequency electromagnetic fields within the operation environment must not ex-
Internal or
external
ignition source
Gas Toxic fumes can be released in case of failure.
Do not touch electrically live parts before the discharge time of 15 min runs up, check
zero-potential before touching.
The device causes electromagnetic fields when operating.
Any person with individual device for cardiac assistance (pacemaker, defibrillator) must
stay in sufficient distance to the operating device.
m Wear safety gloves!
ceed the field strength of the second environment according EN 61800-3.
Internal or external ignition sources are not allowed within the environment of the devices!
m Use ABC powder for extinguishing a fire!
No flammable fume or dust and no flammable/explosive gases are permitted within the
environment of the devices!
Transportation
and mounting
In order to avoid damage to persons because of explosions:
m ventilate the area and
m immediate evacuation.
Falling down of the device can cause damage to persons.
Note the weight of the device when selecting the mounting screws!
Select the fastening torques of the mounting screws according the specification of the
screw manufacturer!
m Wear safety helmets/shoes!
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2.4
Device
Motor cable or
Device
power connection
Motor cable or
power connection
Mounting Unprotected hands can be injured at the sharp edges of the device.
Risk assessment according EU Directive
m We
ar safety gloves!
Unprotected eyes can be injured by thrown up metal particles c
cut-outs.
m Wear safety glasses!
aused by drilling or making
Short-circuit in
power cables
In case of a short-circuit high current flows. This current induces a magnetic field in cable
loops. The magnetic field can cause failures of the device.
To avoid additional damage in case of a short-circuit in power cables,
n The co
must be laid without loop.
nnection between power supply and device or between device and motor
Figure 1: Wiring of the power cables
Installation If a shielded cable is connected unshielded and this causes failure of the device/danger
Brake resistor
ection
conn
Communication
errors
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to persons, the system manufacturer is responsible for.
The dissipation of the heat loss of the external brake resistor must be ensured.
Ensure that a failure of the device w
The safety notes of all further chapters of this documentation need to be carefully observed!
Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
ill cause no danger to persons.
2.5 Responsibility of the operating company
The device is used in commercial areas. Thus, the proprietor of the device is subject to
the legal work safety regulations.
Along with the notes on work safety in these instruction handbook, the safety, accident
prevention and environmental protection regulations valid for the area of application of
this device must be complied with. Whereby:
e operating company must inform himself about the applicable work health and safe-
m Th
ty regulations and ascertain, in a hazard ass
arise from the special working conditions in the use area of the device. These must
then be implemented in the form of instruction handbook for operation of the device.
ese instruction handbook must be kept accessible to personnel working with the de-
m Th
vice at all times in the immediate vicinity of the device.
e specifications of the instruction handbook must be adhered to completely and
m Th
without exception.
e device may only be operated in a technically faultless and operationally safe con-
m Th
dition.
Safety
essment, any additional hazards that could
2
2.6 Protective devices
BM58XX IP 10
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted.
Therefore:
m The device must be in operated inside of a control cabinet that provides protection
against direct contact of the devices and at least meets the requirements of
EN 61800-5-1, Chapter 4.2.3.3.
IP code
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2.7
Training of the personnel
2.7 Training of the personnel
WARNING!
Risk of injury due to insufficient qualifications!
Improper handling can lead to significant personal injury and material damage.
Therefore:
m Certain activities can only be performed by the persons stated in the respective
chapters of these instruction handbook.
In these 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.
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.
-
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2.8 Personal protective equipment
The wearing of personal protective equipment is required when working in order to minimize health and safety risks.
m The protective equipment necessary for each respective type of work shall always be
worn during work.
m The personal safety signs present in each working area must be observed.
Protective work clothing
should be snug-fitting work clothes, with low tearing resistance, narrow sleeves and
with no extending parts. It serves to primarily protect against...
No rings or chains should be worn.
Hard hat
to protect against falling down and flying around objects.
Safety
2
Wear for special
work.
Safety shoes
to protect against heavy objects falling down.
Protective gloves
to protect hands against friction, abrasion, puncturing or more severe injuries, as well
as contact with hot objects.
Protective eye wear
to protect the eyes against flying around objects and sprayed liquids.
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2.9
Special hazards
2.9 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
Instruction handbook 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 rack system = discharge time of the device with the longest DC
link discharge time in the rack system.
Refer to ZElectrical data– from page 36.
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.
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Moving components
2.10 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.
2
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
2
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2.11
Safety equipment
2.11 Safety equipment
WARNING!
Risk of fatal injury due to non-functional safety equipment!
Safety equipment provides for the highest level of safety in a facility. Even if safety
equipment makes work processes more awkward, under no circumstances may they
be circumvented. Safety can only be ensured by intact safety equipment.
Therefore:
m Before starting to work, check whether the safety equipment in good working order
and properly installed.
2.12 Conduct in case of danger or accidents
Preventive
measures
And if something
does happen:
respond 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 alarm, first aid and rescue 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 at the scene of operations.
m Alarm medical personnel and/or the fire department.
m Keep access routes clear for rescue vehicles.
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2.13 Signs and labels
The following symbols and information signs are located in the working area. They refer
to the immediate vicinity in which they are affixed.
WARNING!
Risk of injury due to illegible symbols!
Over the course of time, stickers and symbols on the device can become dirty or otherwise unrecognizable.
Therefore:
m Maintain all safety, warning and operating labels on the device in easily readable
condition.
Safety
2
Electrical voltage
Only qualified personnel may work in work areas that identified with this.
Unauthorized persons may not touch working materials marked correspondingly.
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the rack system = discharge time of the device with the longest DC
link discharge time in the rack system.
Refer to ZElectrical data– from page 36.
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 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.
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2.13
Signs and labels
CAUTION!
Risk of injury due to hot surface!
When in operation, the top of the device can heat up to temperatures > 70 °C!
Therefore:
m Wear protective gloves
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Abbildung 2: Signs and labels BM58XX
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Safety
2
Signs and labels
devices
with safety level
NOTE!
Only a device, marked with the TÜV Rheinland certification label and the safety label
fulfills a certified safety function within the meaning of PL classification according
ISO 13849 or SIL according EN 61800.
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2.13
Signs and labels
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3.1 Dimensions
3TECHNICAL DATA
The following drawings show the main dimensions of the devices in millimeters [mm]. The
space requirements in the control cabinet are also determined based on these drawings.
To make the necessary drill holes/cutout sections, use the drawings inZDrilling pattern–
from page 65.
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3.1
3.1.1 BM5807-S dimensions
Dimensions
Standard air cooling, cooling within the control cabinet.
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Figure 3: BM5807-S dimensions
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*: Observe minimum clearance
Please follow the notes for mounting and ZCooling–
on page 35.
3.1.2 BM5807-A dimension
Air cooling outside the control cabinet, through hole air cooling
Technical data
3
3.2 Weight
Figure 4: BM5807-A dimensions
Device Weight
BM580
BM580
7-S Max. 12 kg
7-A Max. 10 kg
Instruction handbook b maXX 5800
*: Observe minimum clearance
Please follow the notes for mounting and ZCooling–
on page 35.
29
Document No. 5.16027.04
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3.3
Power supply
Operating conditions
3.3 Operating conditions
3.3.1 Requirements for control voltage / 24 V power supply
Figure 5: Control voltage / 24 V power supply
NOTE!
The input current of the 24 V power supply is limited to 16 A when using a BM5800
multi-axis controller. If several double axis modules with several brakes are used, the
maximum brake current of all integrated axis modules is limited to 12 A.
3.3.2 Requirements for the motor
The b maXX 5800 is designed to operate three phase current motors with a motor terminal voltage of 3 x 350 V (typical for servo motors from Baumüller) or 3 x 400 V (typical for
standard asynchronous motors and for customer-specific special motors from
Baumüller). The motors must be operated in a star connection. The rated DC link voltage
is 540 V
in brake operation. The connected motor must be designed to handle these DC link voltages.
If b maXX 5800 axis units are operated with a voltage-controlled DC link (e.g. BM51XX),
then the DC link voltage will be permanently (not only in brake operation)
between 640 V and 760 V. The connected motor must be designed to be operated at
these voltages in continuous operation.
It is also possible to operate the devices at lower voltages, e.g. 3 x 230 V. A prerequisite,
however, is that the three phase current motors used for operation with converters rated
for an DC link voltage of up to 800 V, as the brake resistor voltage (refer to ZElectrical
data– from page 36) remains unchanged.
Thus, only three phase current motors with U
cases as well.
. It can be expected that the DC link voltage increases to up to 780 V or 800 V
DC
DC link, rated
540 V may be used in these
30
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Technical data
3.3.3 Required environmental conditions
Transport temperature range - 25 °C bis + 70 °C
3
Transport climate class (K)
EN 60721-3-2
2 K 3
Storage temperature range - 25 °C bis + 55 °C
Storage climate class
EN 60721-3-1
1 K 4
Operational temperature range Min. 5 °C to max. 55 °C
(with derating above 40 °C)
Operational climate class
EN 60721-3-3
3 K 3
Operational altitude Up to 4000 m above MSL
(with derating above 1000 m)
Humidity (operating)
EN 60721-3-3
Relative humidity: 5% to 85% non-condensed,
and
absolute humidity: 1 g/m
3
to 25 g/m
Ionizing and non-ionized radiation < measurable range
Vibration, shock and continuous shock
EN 61800-5-1, chapter 5.2.6.4 vibration test
Degree of contamination
EN 61800-5-1, table 6, tab. 2
Max. 0.5 g when operating
2
2)
2)
3
1)
If used in areas according to the category C2 of IEC 61800-3:2012, additional measures might be necessary. In this case the plant
manufacturer / user has to provide evidence these additional measures take effect and the in IEC 61800-3 required thresholds of the
category C2 are met.
2)
Refer to correction values at changed operation conditions at ZCorrection values for the output current– from page 32.
NOTICE!
Normally only a non-conductive dirt buildup occurs. Any conductive dirt buildup,
whether short-term or permanent, is prohibited and could lead to destruction of the
device. The customer is responsible for destruction resulting from dirt buildup of conductive materials or matter.
Instruction handbook b maXX 5800
Document No. 5.16027.04
31
of 174
3.3
Operational temperature T
U
k
T
Correction value temperature
Air-cooled
Water-cooled/Cold plate
3.3.4 Correction values at changed operation conditions
3.3.4.1 Correction values for the output current
Operating conditions
The correction values of the permitted output power and output current must be multiplied, if the devices b maXX 5800 are used at operation conditions with different correction values.
The following correction values are to be considered if nothing other is specified at the
„Electrical data“ of the device:
32
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Figure 6: Correction value kT in dependence of the temperature T
U
Installation altitude H
k
H
Correction value installation altitude
Technical data
I
permitted
I
ratedkTkH
=
kTkH0,79
3
Figure 7: Correction value kH in dependence on the installation altitude H
The permitted output current I
ing following formula:
I
= Output rated current at 40 °C and up to 1000 m,
rated
. kH > 1, then I
If k
T
an output current higher than I
NOTICE!
The following condition must always be met to prevent the device of overload:
permitted
refer to ZElectrical data– from page 36.
(adjusted output rated current) is calculated accord-
permitted
= I
,
rated
is not possible.
rated
If k
. kH > 1, the operation of the device is permitted and I
T
Instruction handbook b maXX 5800
Document No. 5.16027.04
permitted
is limited to I
rated
of 174
.
33
3.3
Operating conditions
Examples: k
T (25 °C)
k
H (3000 m)
k
T (25 °C)
k
T (20 °C)
k
H (1500 m)
k
T (20 °C)
k
T (40 °C)
k
H (4000 m)
k
T (40 °C)
= 1.2
= 0.8
* k
H (3000 m)
= 1.27
= 0.95
* k
H (1500 m)
= 1
= 0.7
* k
H (4000 m)
= 0.96 0.79 Operation permitted
= 1.20 0.79 Operation permitted
= 0.7 < 0.79 Operation not permitted
3.3.4.2 Correction values DC link voltage
I
permitted
I
permitted
= I
= I
rated
rated
. 0.96
BM58XX
Output current [%]
The device supplies the rated/peak currents at rated DC link voltage.
The output currents must be reduced accordingly when operating with a DC link voltage
is higher than 640 V and output power remains constant.
DC link voltage [V]
Figure 8: Derating: Output current as function of the DC link voltage
34
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
3.3.5 Cooling
Technical data
3
Cooling air temperature
Cooling air requirement
1)
Air temperature in the entire intake area of the device.
2)
The cooling air requirement corresponds to at least that of a freely-blowing device. Freely-blowing means that the air flow in and out are
unobstructed. Therefore, when installing the device in a control cabinet, it could be necessary to make use of additional fans in order
that the necessary cooling air requirement is covered. If the necessary cooling air requirement of the passive cooling unit is not provided
for, then the output power of the device must be reduced.
1)
Refer to ZCo
2)
rrection values for the output current– from page 32
refer to ZElec
Min. 5 °C to max. 55 °C
(rated temperature: 40 °C)
Depends on the device,
trical data– from page 36
Figure 9: Cooling air requirement
Instruction handbook b maXX 5800
Document No. 5.16027.04
35
of 174
3.4
Electrical data
3.4 Electrical data
NOTE!
Depending on the configuration up to 3 axis modules with the type code -XXXXXX-
are integrated in the b maXX 5800 device.
The power ratings can be different depending on the cooling type BM5807-XG, too.
Refer to also ZType code– on page 49.
3.4.1 Double axis modules
Input rated power
DC link voltage (U
1) 9)
DC
BM5807-SG
-23XXXX-
3.5 kW 5.75 kW 7.0 kW 9.9 kW
1)
)
BM5807-AG
-23XXXX-
60 V - 760 V
BM5807-SG
-25XXXX-
BM5807-AG
DC link capacity (internal) 235 µF
DC link discharge time (internal DC link capacity) 250 s
Output voltage
Output frequency at 4 kHz
Output rated current
RMS)
1) 2) 5) 11)
(I
AC
Output rated current
1) 2) 5) 11)
RMS)
(I
AC
Output rated current
1) 2) 5) 11)
RMS)
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
RMS)
RMS)
RMS)
1) 5) 6) 11)
1) 5) 6) 11)
1) 5) 6) 11)
(UAC)
1) 3)
0 - 500 V
4)
at 4 kHz
at 8 kHz
at 16 kHz
at 4 kHz
at 8 kHz
at 16 kHz
4)
4)
4)
4)
4)
4)
2 x 3 A 2 x 4.5 A 2 x 6 A 2 x 8.5 A
2 x 2.1 A 2 x 3.15 A 2 x 4.2 A 2 x 5.9 A
2 x 9 A 2 x 18 A
2 x 6.3 A 2 x 12.6 A
0 - 450 Hz
-
-
Short-time operation KB 300 % 200 % 300 %
Max. length of time peak current
6)
Refer to ZLoad cycle accor
ding EN61800-6– from page 42
-25XXXX-
Power loss with regard to power supply Max. 55 W Max. 82.5 W Max. 100 W Max. 141 W
Power loss with regard to
control voltage supply
Current of the integrated brake control
(option)
7)
8)
Max. 35 W
Max. 2 x 2.0 A
12)
Cooling air requirement power heat sink 15 m3/h - 15 m3/h -
Cooling air velocity power heat sink - > 5 m/s - > 5 m/s
Footnotes refer to ZPage 40–.
36
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Technical data
3
Input rated power
DC link voltage (U
1) 9)
DC
BM5807-
SG
-31XXXX-
1)
)
BM5807-
AG
-31XXXX-
BM5807-
SG
-32XXXX-
BM5807-
AG
-32XXXX-
BM5807-
SG
-33XXXX-
BM5807-
-33XXXX-
13.4 kW 22.4 kW 33.6 kW
60 V - 760 V
DC link capacity (internal) 330 µF 660 µF 1175 µF
DC link discharge time (internal DC link
240 s 480 s 900 s
capacity)
Output voltage
Output frequency at 4 kHz
Output rated current
(I
AC
Output rated current
(I
AC
Output rated current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
RMS)
RMS)
RMS)
RMS)
RMS)
RMS)
1) 2) 5) 11)
1) 2) 5) 11)
1) 2) 5) 11)
1) 5) 6) 11)
1) 5) 6) 11)
1) 5) 6) 11)
(UAC)
1) 3)
4)
at 4 kHz
at 8 kHz
at 16 kHz
at 4 kHz
at 8 kHz
at 16 kHz
0 - 500 V
0 - 450 Hz
4)
4)
4)
4)
4)
4)
2 x 12 A 2 x 20 A 2 x 30 A
2 x 28 A with UL
2 x 8.4 A 2 x 14 A 2 x 21 A
2 x 4.8 A 2 x 8 A 2 x 12 A
2 x 24 A 2 x 40 A 2 x 60 A
2 x 16.8 A 2 x 28 A 2 x 42 A
2 x 9.6 A 2 x 16 A 2 x 24 A
Short-time operation KB 200 %
Max. length of time peak current
6)
Refer to ZLoad cycle according EN61800-6– from page 42
AG
Power loss with regard to power supply Max. 210 W Max. 310 W Max. 460 W
Power loss with regard to control voltage supply
Current of the integrated brake control
(option)
7)
8)
Max. 42 W Max. 55 W
Max. 2 x 2.0 A
12)
Cooling air requirement power heat sink 55 m3/h - 55 m3/h - 100 m3/h -
Cooling air velocity power heat sink - > 5 m/s - > 5 m/s - > 5 m/s
Cooling air requirement internal space
3
10 m
/h - 10 m3/h - 10 m3/h -
of device
Footnotes refer to ZPage 40–.
Instruction handbook b maXX 5800
Document No. 5.16027.04
37
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3.4
Electrical data
3.4.2 Single axis modules
Input rated power
DC link voltage (U
1)
DC
BM5807-SG
-22XXXX-
1.75 kW 2.8 kW 3.5 kW 5 kW
1)
)
BM5807-AG
-22XXXX-
60 V - 760 V
BM5807-SG
-24XXXX-
BM5807-AG
DC link capacity (internal) 235 µF
DC link discharge time (internal DC link capacity) 250 s
Output voltage
Output frequency at 4 kHz
Output rated current
(I
AC
Output rated current
(I
AC
Output rated current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
RMS)
RMS)
RMS)
RMS)
RMS)
RMS)
1) 2) 5) 11)
1) 2) 5) 11)
1) 2) 5) 11)
1) 5) 6) 11)
1) 5) 6) 11)
1) 5) 6) 11)
(UAC)
1) 3)
0 - 500 V
4)
at 4 kHz
at 8 kHz
at 16 kHz
at 4 kHz
at 8 kHz
at 16 kHz
4)
4)
4)
4)
4)
4)
3 A 4.5 A 6 A 8.5 A
2.1 A 3.15 A 4.2 A 5.9 A
9 A 18 A
6.3 A 12.6 A
0 - 450 Hz
-
-
Short-time operation KB 300 % 200 % 300 %
Max. length of time peak current
6)
Refer to ZLoad cycle accor
ding EN61800-6– from page 42
-24XXXX-
Power loss with regard to power supply Max. 55 W Max. 82.5 W Max. 100 W Max. 141 W
Power loss with regard to
control voltage supply
Current of the integrated brake control
(option)
7)
8)
Max. 30 W
Max. 2.0 A
12)
Cooling air requirement power heat sink 15 m3/h - 15 m3/h -
Cooling air velocity power heat sink - > 5 m/s - > 5 m/s
Footnotes refer to ZPage 40–.
38
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Technical data
3
Input rated power
DC link voltage (U
1)
DC
BM5807-
SG
-26XXXX-
1)
)
BM5807-
AG
-26XXXX-
BM5807-
SG
-27XXXX-
BM5807-
AG
-27XXXX-
BM5807-
SG
-28XXXX-
BM5807-
-28XXXX-
6.7 kW 11.2 kW 16.8 kW
60 V - 760 V
DC link capacity (internal) 165 µF 330 µF 495 µF
DC link discharge time (internal DC link
120 s 240 s 450 s
capacity)
Output voltage
Output frequency at 4 kHz
Output rated current
(I
AC
Output rated current
(I
AC
Output rated current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
Output peak current
(I
AC
RMS)
RMS)
RMS)
RMS)
RMS)
RMS)
1) 2) 5)11)
1) 2) 5)11)
1) 2) 5)11)
1) 5) 6)11)
1) 5) 6)11)
1) 5) 6)11)
(UAC)
1) 3)
4)
at
4 kHz
at
8 kHz
at
16 kHz
at
4 kHz
at
8 kHz
at
16 kHz
0 - 500 V
0 - 450 Hz
4)
4)
4)
4)
4)
4)
12 A 20 A 30 A
28 A at UL
8.4 A 14 A 21 A
4.8 A 8 A 12 A
24 A 40 A 60 A
16.8 A 28 A 42 A
9.6 A 16 A 24 A
Short-time operation KB 200 %
Max. length of time peak current
6)
Refer to ZLoad cycle according EN61800-6– from page 42
AG
Power loss with regard to power supply Max. 105 W Max. 155 W Max. 230 W
Power loss with regard to control voltage
supply
Current of the integrated brake control
(option)
7)
8)
Max. 40 W Max. 45 W
Max. 2.0 A
12)
Cooling air requirement power heat sink 10 m3/h - 20 m3/h - 35 m3/h -
Cooling air velocity power heat sink - > 5 m/s - > 5 m/s - > 5 m/s
Cooling air requirement internal space of
3
10 m
/h - 10 m3/h - 10 m3/h -
device
Footnotes refer to ZPage 40–.
Instruction handbook b maXX 5800
Document No. 5.16027.04
39
of 174
3.4
f
max
f
I-R
K
pf
------- -
, typical K
Pf
18=
Electrical data
1)
All rated values are based on a DC link voltage of 640 V, a control voltage of 24 V and a surrounding temperature of 40 °C and the switching frequency specified.
2)
The input current must be reduced between 40 °C and 55 °C, refer to correction values at changed operation
conditions ZFigure 6– on
3)
The output voltage is a pulsed direct voltage. The adjusting range is based on the RMS-value of the fundamental wave.
4)
The range of the output frequency is based on a stationary operation in the linear range of the PWM, i. e.
without overmodulation.
The quality of the generated output voltages depends on the ratio between output frequency and current controller frequency f
The maximum output frequency f
Furthermore the controller sets an upper limit for the output frequency of 599 Hz (please contact the responsible Baumüller sales department, keyw
*)
900 Hz could be generated by the controller
The device is able to generate output voltages with frequencies between f
allows that, however the quality of this voltages cannot be guaranteed.
Typical the devices are marked with the max outpu
5)
The device supplies the rated/peak currents at rated DC link voltage.
The output currents must be reduced accordingly when operating with a DC link voltage is higher than 640
V and output pow
on page 34
6)
The actual possible overload time depends on the preloading of the device and the heat sink temperature
and is detected by the overload monitoring of the device.
Assumption: initial conditions before the overload occu
7)
Without loads on the digital outputs and motor brake.
8)
Short-circuit protected for a maximum of 1 minute.
9)
This power rating is the total power rating of both axes.
10)
120 s for BM5807-SG-, refer to ZCooling– from page 35
11)
The continuously permitted output current must be reduced complying with ZOutput frequency-dependent
current derating– on
between 0 and 15 Hz for over 5 seconds.
12)
page 32.
( f
= 1/cycle time current controller).
I-R
I-R
, generated with high quality, is calculated as follows:
max
ord: export restriction).
PWM frequency Current controller
le time
cyc
Range of the output frequency
2 kHz 250 µs 0 - 225 Hz
4 kHz 125 µs 0 - 450 Hz
8 / 16 kHz 62.5 µs 0 - 599 Hz (900 Hz
and 599 Hz and the controller
max
t frequency at 4 kHz switching frequency: 0 ... 450 kHz.
er remains constant, refer to ZDer
ating: Output current as function of the DC link voltage–
rrence: heat sink temperature 40 °C, I = 0 A,
page 41, if the statical output frequency is lower than 15 Hz and the frequency remains
*)
)
40
of 174
NOTE!
The input current of the 24 V power supply is limited to 16 A when using a BM5800 multi-axis controller. If
several double axis modules with several brakes are used, the maximum brake current of all integrated
axis modules is limited to 12 A, refer to ZX200 (
SELV/PELV)– on page 92.
Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
3.4.3 Output frequency-dependent current derating
All Baumüller devices have been developed so that the rated output current, as stated,
are only continuously permitted (i. e. in S1 operation) with an electrical output frequency
of 15 Hz or higher. If the static inverter output frequency is smaller than 15 Hz and the
frequency is between 0 and 15 Hz for more than 5 seconds, then the continuously permissible output current must be reduced according to the following characteristic curve.
These are affected, for example, but not exclusively:
lications with rpm control but without positioning, or
n App
n Applic
n App
Thus, typically, the following applications are not affected:
n Generally, typical positioning applic
n Applic
n Applic
Insofar as the derating range has been cycled through with sufficient speed, the application of I
quency change corresponds to 15 Hz/s.
Derating of the motor-side inverter output current I with respect to the rated output current
I
rated
ations in which a current is required to assure a torque / a force at standstill or
lications in which blockage of the mechanical parts can occur, e.g. when starting
up cold extruders.
ations with motors that use a service brake when at standstill.
ations in which the higher-level control unit has standstill and blockage monitor-
ing.
is permitted. Here, cycled through with sufficient speed means that the fre-
rated
as a function of the static inverter output frequency f.
ations
Technical data
3
I
I
rated
Static inverter output frequency f
Figure 10: Derating with a static inverter frequency < 15 Hz
Instruction handbook b maXX 5800
Document No. 5.16027.04
41
of 174
3.4
Electrical data
3.4.4 Load cycle according EN61800-6
Operation with constant load
Figure 11: Typical current-time diagram: operation with constant load
BM5807-
Ib at 2 kHz Ib at 4 kHz Ib at 8 kHz Ib at 16 kHz
-SG-23XXXX - 2 x 3 A (100 % I
-SG-24XXXX - 2 x 6 A (100 % I
-XG-26XXXX - 12 A (100 % I
-XG-27XXXX - 20 A (100 % I
-XG-28XXXX - 30 A (100 % I
-XG-31XXXX - 2 x 12 A (100 % I
-XG-32XXXX - 2 x 20 A (100 % I
-XG-33XXXX - 2 x 30 A (100 % I
-XG-34XXXX - 40 A (100 % I
-XG-35XXXX - 60 A (100 % I
) 2 x 2.1 A (70 % IN) -
N
) 2 x 4.2 A (70 % IN) -
N
) 8.4 A (70 % IN) 4.8 A (40 % IN)
N
) 14 A (70 % IN) 8 A (40 % IN)
N
) 21 A (70 % IN) 12 A (40 % IN)
N
) 2 x 8.4 A (70 % IN) 2 x 4.8 A A (40 % IN)
N
) 2 x 14 A (70 % IN) 2 x 8 A (40 % IN)
N
) 2 x 21 A (70 % IN) 2 x 12 A (40 % IN)
N
) 28 A (70 % IN) 16 A (40 % IN)
N
) 42 A (70 % IN) 24 A (40 % IN)
N
42
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
tpto+I
rated
2
tpI
p
2
=
NOTE!
Precondition for the following load cycles:
Output frequency 100 Hz!
Intermittent load cycle with peak value
Technical data
3
Figure 12: Typical current-time diagram: intermittent load cycle with peak value
This term is valid for possible load cycles:
BM53XX
t
o
-SG-23XXXX 10 s - - 3.3 s (IP = 6 A) 1.1 s (IP = 9 A)
-SG-24XXXX 10 s - - 3.3 s (I
-XG-26XXXX 18 s - - 6 s (I
-XG-27XXXX 18 s - - 6 s (I
-XG-28XXXX 18
-XG-31XXXX 18 s - - 6 s
-XG-32XXXX 18 s - - 6 s
-XG-33XXXX 18 s - - 6 s
-XG-34XXXX 16 s 7 s - Not allowed Not allowed
-XG-35XXXX 6 s - - 2 s Not allowed
tp with IP = 150 % INtp with IP = 166 % I
s - - 6 s (IP = 24 A) Not allowed
tp with IP = 200 % I
N
tp with IP = 300 % I
N
= 12 A) 1.1 s (IP = 18 A)
P
= 24 A) Not allowed
P
= 24 A) Not allowed
P
(IP = 24 A) Not allowed
(IP = 24 A) Not allowed
(IP = 24 A) Not allowed
N
Instruction handbook b maXX 5800
Document No. 5.16027.04
43
of 174
3.4
tbtb+I
rated
2
tpI
p
2
tbI
b
2
+=
Electrical data
Intermittent load cycle
Figure 13: Typical current-time diagram: Intermittent load cycle
This term is valid for possible load cycles:
BM5807
tb with
I
= 60 % I
b
-SG-23XXXX 60 s(Ib = 1,8 A) 4.8 s
-SG-24XXXX 60 s(I
-XG-26XXXX 60 s(I
-XG-27XXXX 60 s(I
-XG-28XXXX 60 s(I
-XG-31XXXX 60 s(I
-XG-32XXXX 60 s(I
-XG-33XXXX 60 s(I
-XG-34XXXX 150 s(I
-XG-35XXXX 4.7 s (I
= 3,6 A) 4.8 s (
b
= 7.2 A) Not allowed 10 s (IP = 24 A) - 600 s (Ib = 7.2 A) 150 s (IP = 18 A)
b
= 12 A) Not allowed 10 s (IP = 40 A) - 600 s (Ib = 12 A) 150 s (IP = 30 A)
b
= 18 A) Not allowed 10 s (IP = 60 A) - 600 s Ib = 18 A) 150 s (IP = 45 A)
b
= 7,2 A) Not allowed 10 s (IP = 24 A) - 600 s (Ib = 7.2 A) 150 s (IP = 18 A)
b
= 12 A) Not allowed 10 s (IP = 40 A) - 600 s (Ib = 12 A) 150 s (IP = 30 A)
b
= 18 A) Not allowed 10 s (IP = 60 A) - 600 s Ib = 18 A) 150 s (IP = 45 A)
b
= 24 A) Not allowed Not allowed 30 s
b
= 36 A) Not allowed 1 s (IP = 120 A) - 150 s (Ib = 36 A) 30 s (IP = 120 A)
b
I
N
P
(I
P
I
= 18 A)
P
tp with
= 300 % I
= 9 A)
N
I
= 200% I
P
12.8 s (I
12.8 s (I
tp with
N
= 6 A) - 600 s (Ib = 1,8 A) 240 s (IP = 4.5 A)
P
= 12 A) - 600 s (Ib = 3.6 A) 240 s (IP = 9 A)
P
tp with
I
= 150% I
P
(I
= 60 A)
P
tb with
I
N
= 60 % I
b
150 s (I
N
= 24 A) 30 s (IP = 60 A)
b
tp with
I
= 150 % I
P
N
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Document No. 5.16027.04 Baumüller Nürnberg GmbH
4.1 Design
The b maXX 5000 series consists of an (active) mains rectifier unit and one or more axis
units, double axis units or multi-axis controllers. The possible number of axis units and
multi-axis controllers depends on the connected load of the DC link of the mains rectifier
unit.
b maXX 50XX Mains rectifier unit
is a mains rectifier unit for supplying multi-axis controllers BM5800 and other axis
This
units via the DC link.
The applied AC voltage at the three phase power system is transformed by a rectifier on
the input side into DC voltage. The DC link capacitors smooth this DC voltage.
b maXX 51XX Active mains rectifier unit
is an active mains rectifier unit for supplying multi-axis controllers BM5800 and other
This
axis units via the DC link.
The applied AC voltage at the three phase power system is transformed by a rectifier on
the input side into DC voltage. The DC link capacitors smooth this DC voltage. The active
mains rectifier unit can feed back excess braking energy into the mains as sinusoidal
electrical current.
4DESIGN AND OPERATION
b maXX 53XX
Single axis unit safety, double axis unit safety
This is a motor inverter that is supplied from a mains rectifier unit or active mains rectifier
unit via the DC link.
From the DC voltage at the DC link, the inverter on the output side produces a threephase current system with variable frequency and voltage for operation of the connected
motor.
NOTE!
rrect operation of the b maXX axis units BM53XX can only be ensured in combi-
Co
nation with Baumüller mains rectifier units BM50XX, BM51XX or basic units
BM4XXX / BM5XXX.
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4.1
b maXX 58XX Multi-axis controller safety
Design
This is a motor inverter that is supplied from a mains rectifier unit or active mains rectifier
unit via the DC link.
From the DC voltage at the DC link, the inverters on the output side produce a threephase current system with variable frequency and voltage for operation of several connected motors.
Up to 6 axes can be controlled simultaneously, independently from each other and with
different output currents by the multi-axis controller b maXX 58XX.
The multi-axis controller b maXX 58XX is available with a width of 175 mm and the following cooling variants: standard air (-S) standard air 180 ° rotated and standard air
through-hole (-A).
Depending on the required integrated axis modules 2 or 3 power types can be selected.
m 3 x 50 mm
m 2 x 50 mm + 1 x 75 mm
m 1 x 50 mm + 1 x 75 mm
m 2 x 75 mm
For example following combinations can be realized:
Width 175 mm
3 double axis modules
(6 axes controller)
2 double axis modules
(4 axes controller)
3 double axis modules
(6 axes controller)
2 double axis modules
(4 axes controller)
and so on.
.
NOTE!
Correct operation of the b maXX multi-axis units BM58XX can only be ensured in
combination with Baumüller mains rectifier units BM50XX, BM51XX or basic units
BM4XXX / BM5XXX.
2 x 8,5 A
50 mm
2 x 6 A
50 mm
2 x 20 A
75 mm
2 x 30 A
75 mm
2 x 4,25 A
50 mm
2 x 6 A
50 mm
2 x 8,5 A
50 mm
2 x 6 A
50 mm
2 x 4,25 A
50 mm
2 x 8,5 A
50 mm
Controller The controller unit controls the inverter of the power unit. The controller is operated either
b
y means of operating software or by means of a higher-level control unit.
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4.2 Identification of the device
4.2.1 Part number
Design and Operation
4
Figure 14: Part number - front
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4.2
4.2.2 Type plate
Identification of the device
Examples of the locations where the type plate is affixed are shown in the figure.
Among other things, the type plate also shows the type code of the device.
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Figure 15: Affixing of the type plate
Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Design and Operation
4.2.3 Type code
The type code has the format:
BM58XX -XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX
The type code is explained in the following table.
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Device generation
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Device design
0: Mains rectifier
1: Active mains rectifier
3: Axis unit safety
5: Basic unit/power module safety
6: Basic unit/power module safety,
optimized for peak current
7: Basic unit/power module safety,
optimized for rated current, water-cooled
8: Multi-axis controller safety
4
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Housing size
07: 175 mm width,
refer to ZDimensions– from page 27.
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Type of cooling
S: Air-cooled with air supply and with air outlet in the
control cabinet
A: Air-cooled with air supply and with air outlet out-
side the control cabinet - through-hole device
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Type of power supply system
G: Multi-axis controller,
mains inverter connected to Grounded delta
systems, IT systems, grounded TN or TT systems
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4.2
Identification of the device
Axis module 1 Axis module 2 Axis module 3
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Axis module 1 / 2 / 3
00 Not existing
22 1 x 3 A
22 1 x 4,5 A (cooling type A, only)
23 2 x 3 A
23 2 x 4,5 A (cooling type A, only)
24 1 x 6 A
24 1 x 8,5 A (cooling type A, only)
25 2 x 6 A
25 2 x 8,5 A (cooling type A, only)
26 1 x 12 A
27 1 x 20 A
28 1 x 30 A
31 2 x 12 A
32 2 x 20 A
33 2 x 30 A
34 1 x 40 A in preparation
35 1 x 60 A in preparation
36 2 x 40 A in preparation
37 2 x 60 A in preparation
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Motor brake power unit 1 / 2 / 3
0: No axis module
2: With motor brake
3: Without motor brake
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Encoder evaluation
0: No encoder or no axis module
1: HIPERFACE®, EnDat® 2.1, SSI, square wave
and sine incremental encoder, resolver
2: EnDat® 2.2
3: HIPERFACE® DSL
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Safety function
0: No safety function or no axis module
1: With safety function STO
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX I/O configuration
0: No I/O function or no axis module
1: 1 touch probe input
2: 2 touch probe inputs
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Controller hardware type
00: MSCsafe without DIO, without AIO, without
display, without parameterization interface, with
2 LEDs
01: MSCsafe with all options
02. MSCsafe without DIO
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Design and Operation
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Fieldbus configuration
0: No fieldbus
1: EtherCAT® CoE
2: VARAN
3: CANopen
4: POWERLINK
5: Profinet IRT
6: Sercos® III
7: EtherCAT® SoE
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Additional functions
00: No additional function
10: Connection of external power units
01: IEE with external power supply
03: SIE with internal power supply
04: SVP-001-001
05: SVP-001-002
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Special requests
00: Standard
01: Varnished PCB
02: 180° rotated
®
4
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Firmware
XXXX: Incompatible firmware release
XXXX: Firmware release version
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XXX-XXXX-XXXX-EXX Software functionality
00: Standard device
01: SoftDrivePLC
02: Servo pump functionality V1
(including SoftDrivePLC project)
03: Servo pump functionality V2
(including SoftDrivePLC project)
04: CLDP functionality V1
(including SoftDrivePLC project)
80: Export device (no dual use)
with 600Hz limit of output frequency
81: Export device with SoftDrivePLC
83: Export device with servo pump functionality V1
(including SoftDrivePLC project)
84: Export device with servo pump functionality V2
(including SoftDrivePLC project)
85: Export device with CLDP functionality V1
(including SoftDrivePLC project)
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4.3
UL notes
4.3 UL notes
The notes below must be observed in case you consider UL 508 C.
quired environmental conditions– on page 31
ZRe
n Note the maximum s
n Use in a pollution
sign– on page 45
ZDe
n Multi axis control
rectifiers (BM5031, BM5032, BM5043, BM5044, BM5174).
stallation procedure– on page 85
ZIn
n Internal
load.
nnections BM5800– from page 89
ZCo
n Position of wiring terminals to indic
supply, load, control circuit, and similar devices refer to ZPage
Connections ZPage 91– and ZPage
n Note tightening to
quirements for the connection cables– on page 75
ZRe
n Use 60°/75°copper
overload protection operates after exceeding 200 % of the motor full
urrounding air temperature.
degree 2 environment only.
ler are allowed to be used only in combination with mains
ate the proper connections for the power
92–
rque values marked for field terminals.
wires only.
89–.
quirements for the motor temperature sensors– on page 84
ZRe
n Drives do not prov
nting of the DC link bar– from page 69 and ZDC link bar– on page 154
ZMou
n Proper installatio
page 69 and p
roper DC link bar refer to ZDC link bar– on page 154.
ide motor overtemperature sensing.
n of the DC link bar, refer to ZMounting of the DC link bar– from
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4.4 Display and operating elements
NOTE!
Depending on the configuration not all display and operating elements are available!
4.4.1 Minimum configuration BM58XX
H1
H2
Design and Operation
4
Fieldbus, depending on the type
(refer to ZType
LED
H31
H32
H41
H42
Figure 16: Display elements minimum configuration BM58XX
Meaning:
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX1BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX7-
ED EtherCAT® .– on page 57
ZL
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX2-
ZLED VARAN– o
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX4-
POWERLINK® .– on page 58
ZLED
code– from page 49)
n page 57
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4.4
Display and operating elements
4.4.2
Maximum configuration BM58XX
X1 Service interface (option)
H1
H2
LED
H21 - H24
H11 - H14
7 segment display 1 (option)
7 segment display 2 (option)
Display controller state
Meaning refer to ZO
LED 1 (option)
LED 2 (option)
Meaning refer to ZOp
ption: 7-segment display– on page 56
tion: LED display– on page 55.
Fieldbus, depending on the type
(refer to ZT
LED
H31
H32
H41
H42
Figure 17: Display elements maximum configuration BM58XX
NOTE!
Only the service cable BM5-K-USB-XXX is allowed to be used for the service interface X1, refer to ZSTO function option– on page 110 and ZEncoder cables– from
page 144.
Meaning:
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX1BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX7-
ZLED EtherCAT
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX2-
ZLED VA
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX4-
ZLED POWERL
ype code– from page 49)
®
.– on page 57
RAN– on page 57
INK® .– on page 58
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4.4.2.1 LED display
Design and Operation
4
Naming on the
front plate
H1 Power on / pulse enable 24 V available
H1 green: Power ON
H2 Error display
H2 rot: Error state device
4.4.2.2 Option: LED display
Naming on the
front plate
H11 1.1 green
H12 1.2 green
Internal
identification
Axis: Torque direction
1.1 red
Axis: Power on / pulse enable 24 V available
1.2 red
Meaning
H11 green: Positive torque direction
H11 red: Negative torque direction
H12 green: Power ON
H12 red:
Meaning
H13 1.3 Axis: Current limit
H13 red: Device operates on current limit
H14 1.4 Axis: Error display
H14 red: Device error message
H21 2.1 green
2.1 red
H22 2.2 green
2.2 red
H23 2.3 Axis: Current limit
H24 2.4 Axis: Error display
Axis: Torque direction
H21 green: Positive torque direction
H21 red: Negative torque direction
Axis: Power on / pulse enable 24 V available
H22 green: Power ON
H22 red:
H23 red: Device operates on current limit
H24 red: Device error message
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4.4
4.4.2.3 Option: 7-segment display
Display and operating elements
Refer to parameter manual for detailed description of drive states and state transitions.
0: Low, 1: High
Display State
drive manager
0
1
2
3
4
5
6
7
E
NOT READY TO SWITCH ON Drive message „Not ready for switching power on“
SWITCH-ON INHIBIT Inhibit voltage, e.g. quick stop active
READY TO SWITCH ON Drive shutdown
SWITCHED ON Control word: xxxx x111
OPERATION ENABLED Control word: xxxx 1111
BETRIEB SPERREN AKTIV
OPERATION INHIBIT ACTIVE Pulse enable = 0
QUICK STOP ACTIVE Quick stop = 0 (low active)
ERROR RESPONSE ACTIVE
Meaning
Control word: xxxx x110
Pulse enable = 0
Quick stop = 1 (low active)
Pulse enable = 1
Quick stop = 1
Pulse enable = 1
Quick stop = 1
F
P
ERROR Error message
Reset via control word 0xxx xxxx
or reset stored errors 0
Parking axis
NOTE!
In addition the error No. is displayed.
➝ 1
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4.4.3 LED display fieldbus
LED EtherCAT® . Type code
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX1BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX7-
Design and Operation
4
Naming on the
front plate
H31 (green) X3 Link / Act Off: No connection
H32 (yellow) ERROR On: ERROR (receiver error Phy1/Phy2)
H41 (green) X4 Link / Act Off: No connection
H42 (yellow) RUN Off: ERROR/INIT
Meaning Blinking pattern
On: Connection
Blinking: Data transfer
On: Connection
Blinking: Data transfer
500 ms on /
500 ms off: PREOPERATIONAL
200 ms on /
1 s off: SAFEOPERATIONAL
On: OPERATIONAL
LED VARAN
Naming on the
front plate
H31 (green)
H41 (green)
H32 (yellow)
H42 (yellow)
LED CANopen
Type code
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX2-
Meaning Blinking pattern
LINK On: Connection between 2 PHYs
ACTIVE On: Data is received or transmitted
®
Type code
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX3-
No function
(physical interfaces) is established
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4.4
Display and operating elements
LED
POWERLINK
Naming on the
front plate
H31 (green) X3 Link / Act Off: No connection
H32 (yellow) ERROR Off: NMT_CT3, NMT_CT7, NMT_GT2
H41 (green) X4 Link / Act Off: No connection
H42 (green) STATUS Off: NMT_GS_OFF, NMT_GS_INITIALISATION,
®
Type code
.
BM58XX-XX-XXXXXX-XXXXXX-XXXXXX-XX4-
Meaning Blinking pattern
On: Connection
Blinking: Data transfer
On: NMT_CT11, NMT_GT6
Blinking: Configuration error (e.g. address seting)
On: Connection
Blinking: Data transfer
NMT_CS_NOT_ACTIVE
50 ms off /
50 ms on: NMT_CS_BASIC_ETHERNET
200 ms on /
1 s off: NMT_CS_PRE_OPERATIONAL_1
2 x 200 ms on /
1 s off: NMT_CS_PRE_OPERATIONAL_2
3 x 200 ms on /
1 s off: NMT_CS_READY_TO_OPERATE
On: NMT_CS_OPERATIONAL
200 ms on /
200 ms off: NMT_CS_STOPPED
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5.1 Safety notes for transport
NOTICE!
Damage due to unauthorized transport!
Transport handled by untrained personnel can lead to a substantial amount of material damage.
Therefore:
m The unloading of the packages upon delivery as well as the in-house transport
should only be done by trained personnel.
m Contact Baumüller Nürnberg GmbH sales office if necessary.
WARNING!
Danger of physical impact!
Secure devices against falling down.
5TRANSPORT AND PACKAGING
Therefore:
m Take suitable measures, such as supports, hoists, straps, etc., to ensure that de-
vice cannot fall down.
m Use appropriate means of transport.
5.2 What to observe when transporting
For initial transport of the device, it is packed at the manufacturer's plant. 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 - 25 °C up to + 70 °C
m Vibration, shock, continuous shock class 2 M 1 as per EN 60721-3-2
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5.3
Transport inspection
5.3 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 conditi
m Note the extent of the damage on the transport do
the transport agent.
m Immediately file a complaint with the freight
writing and immediately contact the responsible representative of Baumüller Nürnberg
GmbH.
NOTE!
Th
e device may not be operated if there is visible transport damage!
onally accept it with reservations.
cuments or on the delivery note of
carrier. Have the complaint confirmed in
5.4 Unpacking
After having received the still packaged device:
h Avoid transport shocks and hard
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.
5.5 Disposal of the packaging
The packaging consists of cardboard, plastic, metal parts, corrugated cardboard and/or
wood.
h When disposing of the packaging, comply
jolts, e.g. when putting an item down.
with the national regulations valid.
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The device is intended for mounting in a control cabinet.
Mounting comprises the following steps:
1 Mounting preparation
2 Mounting
6.1 Safety notes
6MOUNTING
(for drilling holes/cutting out sections, refer to ZDrilling pattern– from page 65)
the device (for fixing, refer to ZMounting instructions– on page 66)
NOTE!
Mounting shall only be performed by employees of the manufacturer or by other qualified personnel.
Qualified personnel are persons who – on account of their occupational training, experience, instruction and knowledge of relevant standards and stipulations, accident
prevention regulations and operating conditions – are authorized by the persons responsible for the safety of the facilities to perform the respective activities that are
necessary, while at the same time recognizing and preventing any potential risks.
The qualifications necessary for working with the device are, for example:
m Occupational training or instruction in accordance with the standards of safety en-
gineering for the care and use of appropriate safety equipment.
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6.1
Safety notes
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.
WARNING!
Danger of mechanical impact!
Secure devices against falling down.
Therefore:
m Take suitable measures, such as supports, hoists and assisting personnel, to en-
sure that device cannot fall down.
m Use appropriate means of transport.
NOTICE!
Danger due to electrostatic discharge.
The connecting terminals of the device are partially at risk due from ESD.
Therefore:
Please heed the respective notes.
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Mounting
CAUTION!
Danger due to sharp edges.
If the device is lifted with unprotected hands during mounting, palms or fingers can
be cut. If the device falls, feet could be injured.
6
Figure 18: Danger area near the mechanical mounting
Therefore:
m Ensure that only qualified personnel, who are familiar with the safety notes and as-
sembly instructions, mount this device.
Wear safety gloves.
Wear safety shoes.
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6.2
Preparing for mounting
6.2 Preparing for mounting
Based on the planning documents and the drilling patterns (refer to ZDrilling pattern–
from page 65), the cutout sections and the positions of the attachment drill holes can be
determined.
NOTICE!
Property damage due to conductive contamination.
Therefore:
m When performing installation work of any kind, it must be ensured that no foreign
material (e.g. drill shavings, copper strands, etc.) gets into the device as a result.
m If possible, the drilling of the holes should be done before mounting the device and
the configuring of the cables should take place outside of the control cabinet. If this
is not possible, the device must be appropriately covered.
Remove this covering again prior to start!
CAUTION!
Eye injury due to flung particles.
Metal particles are flung when making the drill holes and the cutout sections.
Therefore:
Wear protective eye wear!
h Preparing drill holes and cutout sections.
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6.2.1 Drilling pattern
BM5807
BM517X
Use the drilling pattern to make the necessary drill holes/cutout sections.
Mounting
NOTE!
Consider the minimum clearances for cooling when making the drill holes.
All dimensions in millimeters [mm].
Further notes refer to ZDimensions– from page 27 and ZCooling– from page 35.
6
Tolerance
specifications
For air-cooled
versions:
How to determine the required space in the control cabinet, refer to ZDimen
page 27.
Drill hole dimensioning ±0.2 mm
Dimensioning openings +1.0 mm
Relative tolerance of discretionary divisions ±0.1 mm
BM5807-S
sions– from
*: Relative tolerance of discretionary divisions: ±0.1 mm
Figure 19: Drilling pattern with mounting rail for BM58XX-S
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6.3
BM5807
BM517X
BM537X
Mounting instructions
For all
versions:
BM5807-S, BM5807-A
*: Relative tolerance of discretionary divisions: ±0.1 mm
Figure 20: Drilling pattern without mounting rail for all versions
6.3 Mounting instructions
There are different mounting procedure.
Each mounting procedure is described in a drawing (refer to ZFigure 21– on page 67 and
ZFigure 22– on page 68).
The screws and washers required for mounting are listed beneath the respective drawing.
Carry out mounting as follows:
vide suitable transport/lifting equipment as needed.
1 Pro
2 Ke
ep suitable fastening components readily available.
3 Mount the device.
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6.3.1 Mounting with mounting rail
After attaching the mounting rail, push the device from below beneath the upper fastening
bolts (1). Then, tilt the device on the mounting plate (2) and slide onto the mounting rail
(3). Finally, tighten the upper fastening and grounding bolts (4).
Mounting
6
Figure 21: Mounting instructions BM58XX-S, with mounting rail
Device BM5807-S
A - Screws 3 x M5
B - Washers 3 x (5,3 x 10)
C - Screws n x M5
D - Mounting rail 1000 mm Refer to Accessories and Spare Parts ZMounting rail– from page 154
1)
Number n depends on the length of the mounting rail
1)
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6.3
6.3.2 Mounting without mounting rail
Mounting instructions
Push the device from below beneath the upper fastening bolts (1). Then, tilt the device on
the mounting plate (2) and slide into the fastening bolts (3). Finally, tighten all fastening
and grounding bolts (4).
Abbildung 22: Mounting instructions BM580XX without mounting rail
Device BM5807
A - Screw 6 x M5
B - Washers 6 x (5,3 x 10)
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6.3.3 Mounting of the DC link bar
Observe the following items when mounting the DC link bar:
m Position o
Position of the screw thread (detail Z) on top.
The correctly mounting of the distance bushin
unit in case of service and ensures the captivity of the distance bushings.
Neck collar screw (1)
DC link bar (2)
Distance bushing (3)
b maXX 5XXX DC link terminal (4)
f the chamber-bevel (detail Y)on bottom
Mounting
gs makes it easier to disassemble the
6
Figure 23: Correctly mounted DC link bar
m Distance bushing and neck collar screw
It is recommended to assemble the neck collar screw and the distance bushing to the
link bar before mounting the DC link bar. The correctly mounting of the distance
DC
bushings makes it easier to disassemble the unit in case of service and ensures the
captivity of the distance bushings.
WRONG
CORRECT
Figure 24: Mounting of the neck collar screw
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6.3
Mounting instructions
m DC link bar
Observe the correct mounting o
affect to the drill hole.
f the DC link bar. There should no mechanical stress
WRONG
Figure 25: Mounting of the DC link bar
NOTE!
The DC link bar must not overlap the first or last fixing bolt of the rack system.
Cut the DC link bar therefore.
CORRECT
6.3.4 Demounting
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NOTE!
The yellow cover plate can be removed when mounting/demounting air-cooled devices and there is not enough space above the device (min. 15 cm) for lifting up the
cover.
This chapter describes the electrical installation of the device. The mechanical mounting
is described in ZMounting– from page 61.
Initial commissioning is described in the parameter manual in the chapter Commissioning.
Prior to installation, ensure that the technical prerequisites have been fulfilled:
1 Check the demands on the electrical mains.
2 Check the requirements for the electrical cables and the provision of corresponding
3 Check the properties of the connections and the specified configuration of the respec-
7.1 Safety notes
7INSTALLATION
cables.
tive cables.
NOTE!
Installation shall only be performed by employees of the manufacturer or by other
qualified personnel.
Qualified personnel are persons who – on account of their occupational training, experience, instruction and knowledge of relevant standards and stipulations, accident
prevention regulations and operating conditions – are authorized by the persons responsible for the safety of the facilities to perform the respective activities that are
necessary, while at the same time recognizing and preventing any potential risks.
The qualifications necessary for working with the device are, for example:
m Occupational training or instruction, and the authorization to commission, ground
and mark electrical power circuits and devices in accordance with the standards of
the safety engineering.
m Occupational training or instruction, in accordance with the standards of work safe-
ty, for the care and use of appropriate safety equipment.
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7.1
Safety notes
WARNING!
Danger due to faulty installation and initial commissioning!
Installation and initial commissioning require qualified personnel with adequate experience. Faulty installation can lead to life-threatening situations or substantial material
damage.
Therefore:
m Only allow installation and initial commissioning to be performed by employees of
the manufacturer or by other qualified personnel.
DANGER!
Risk of fatal injury from electrical current!
Inevitably, when operating this electrical device, certain parts of it are energized with
hazardous voltage.
Therefore:
m Pay heed to areas on the device that could be dangerous during the electrical in-
stallation.
m Pay heed to areas on the device that could still be electrically energized after op-
eration.
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Figure 26: Hazard areas during electrical installation
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Danger from
residual energy
Installation
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the modular system = discharge time of the device with the longest
DC link discharge time in the modular system.
Refer toZElectrical data– from page 36.
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 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.
7
7.2 Voltage test
DANGER!
Risk of fatal injury from electrical current!
During the routine test of these devices, a voltage test is performed by Baumüller
Nürnberg GmbH in accordance with EN 61800-5-1, Section 5.2.3.2. It is thus unnecessary for the customer to do this.
Therefore:
m Subsequent tests of the devices using high voltages may only be performed by
Baumüller Nürnberg GmbH.
m Disconnect the device from the system during high-voltage testing!
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7.3
Demands on the electrical mains
7.3 Demands on the electrical mains
For all important data, refer to ZRequirements for control voltage / 24 V power supply–
from page 30.
Minor deviations from requirements in the electrical mains can lead to malfunctioning of
the device. If the mains supply deviates too much from the requirements, the device can
be destroyed.
The destruction of the device can cause personal injury.
DANGER!
Risk of fatal injury from electrical current!
If the requirements for the electrical mains are not complied, the device can be damaged or destroyed, thereby greatly endangering individuals.
Therefore:
m Prior to installation, ensure that the demands for electrical mains the have been
fulfilled.
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7.4 Requirements for the connection cables
h Take into account IEC/EN 60204-1, chapter 13 when selecting the cable.
h The protective ground cross section of the cable must be compliant with IEC/
EN
60204-1, section 5.2, Tab. 1.
h A fixed connection for the protective ground conductor is mandatorily specified for op-
eration of the device.
h Use copper cable approved for a minimum of 60 °C (drives < 3 x 100 A) or 75 °C
(drives 3 x 100
For further details (e.g. maximum allowable length), refer to ZCabling– from page 135.
A), if comply with UL 508C.
7.5 PE connection and RCD compatibility
Depending on the functional principle, leakage current >3.5 mAAC or >10 mADC can flow
through the protective ground conductor. Consequently, a stationary ground conductor
connection in accordance with EN 61800-5-1 is required.
Installation
7
DANGER!
Risk of fatal injury from electrical current!
This product can cause direct and/or alternating current in the protective ground conductor.
The leakage current, due to the functional principle of the device, can lead to premature triggering of the fault current protective device or generally prevent triggering of
it.
Therefore:
m Wherever a differential current device (RCD) is used for protection in case of direct
or indirect contact, only an RCD of the type B is permitted on the power supply side
of the device.
m Otherwise a different protective measure must be utilized, such as separation from
the surrounding by means of double or enhanced isolation, or separation from the
power supply system by means of an isolating transformer, for example.
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7.6
Grounding concept of MAR and side-by-side mounted system
7.6 Grounding concept of MAR and side-by-side mounted system
m Grounding concept MAR, each device is connected with PE on its own
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Power supply PE rail
Figure 27: Grounding concept MAR, each device is connected with PE on its own
1 (Active) mains rectifier unit: screw terminals for power supply connection and PE
2 Multi axis
3 Multi axis
4 Mo
Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
unting plate, thickness at least 3 mm
controller 175 mm: screw terminals PE and motor connector 3 x (2 x 3-pin)
controller 175 mm: screw terminals PE and motor connector 3 x (2 x 3-pin)
Installation
m Grounding concept MAR, PE-connection from device to device, cooling type S
7
Power supply PE rail
Figure 28: Grounding concept MAR, PE connection from device to device
1 (Active) mains rectifier unit
2 Multi axis
3 Multi axis
4 M
ounting plate, thickness at least 3 mm
NOTE!
The first and last device must be connected directly with PE if the PE connection is
realized from device to device. An accessories kit is available for the connection from
device to device, refer to ZAccessories kit PE connection from device to device– on
page 154, part No. 467439.
controller 175 mm
controller 175 mm
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7.7
Installation requirements with regard to EMC
7.7 Installation requirements with regard to EMC
NOTE!
The emission of radio frequency interference (RFI) is to a great extent dependent on
the wiring, spatial expansiveness and the arrangement of the components in the system. Ensuring electromagnetic compatibility compliance in accordance with legal requirements is therefore only possible on the completely assembled system and is
thus the responsibility of the system manufacturer or proprietor (Section 9 of the
EMVG §6; European EMC law).
NOTE!
The important information on EMC-compliant installation can be found in these instruction handbook. Additional notes on building a CE-compliant system, that are imperative to take heed of, can be found in the Baumüller manual „Filters for Mains
Applications“, 5.09010.
This manual can be obtained from Baumüller Nürnberg GmbH.
In order to have EMC-compliant and problem-free use within the framework of the legislation, the following aspects must be taken into account.
In case of any questions, please contact Sales or the Applications department of
Baumüller Nürnberg GmbH.
m Only use Baumüller motor cables and Baumüller components.
m Use suitable mains filters recommended by Baumüller Nürnberg GmbH.
m Mount all components on a single mounting plate with a continuously good electrically-
conductive surface (e.g. galvanized steel plate).
m Keep the ground connection device/ground plate as short as possible (< 30 cm), using
fine-stranded cables with a large cross section (>10
m When installing, be sure to follow the correct sequence:
Mains inverter-b maXX 5800 - (motor filter) - motor.
m Ensure that the motor cable is continuous, without interruption.
Do not interrupt motor cables with terminals, contactors or fuses, for example.
m If possible route the cables on the surface of the grounded mounting plate
(i. e. the least effective antenna height).
m When routing in parallel, minimum clearance of 20 cm should be observed between
signal and control cables vis-à-vis the power cables.
m Cables of different EMC categories (e.g. signal cables - mains cables and/or motor ca-
bles) should be crossed at a 90 ° angle.
m Contact the major cable shield when laying cables through walls, which separate dif-
ferent EMC areas
m Contact all the cable’s shields on both sides surface-to-surface and also well-conduc-
tive with ground.
mm²).
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7.8 Shielding plan side-by-side mounted system
The shielding of the motor cable as well as of the motor temperature cable must be connected electrically with the mounting plate or with shield sheet (refer to ZShielding con-
nection with shield sheet– on page 80).
NOTE!
Baumüller Nürnberg GmbH recommends the shielding connection with shield sheet.
NOTE!
Pay attention to strain relief for all cables!
Installation
7
7.8.1 Shielding connection mounting plate
Establish a large-area contact between the shield and the conductive and grounded
mounting plate by means of a conductive clamp.
Refer to ZConnecting the shield– from page 81.
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7.8
7.8.2 Shielding connection with shield sheet
7.8.2.1 Mounting shield sheet
Air-cooled
devices
Shielding plan side-by-side mounted system
Refer to ZAccessories kit shielding– on page 153.
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Figure 29: Mounting shield sheet air-cooled devices
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7.8.2.2 Connecting the shield
It is recommended to connect the shielding according following figure, refer to also
ZAccessories kit shielding– on page 153.
epare motor cable according figure
1 Pr
2 Re
move the motor temperature cable’s shield from the cable
3 Wr
ap motor temperature cable around motor cable at least 1 turn, form no loop.
Installation
7
Shield
motor cable
RIGHT
WRONG
Motor temperature
cable
Shield
motor temperature
cable
Motor cable
Figure 30: Wrap shield motor temperature cable around motor cable
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7.8
Shielding plan side-by-side mounted system
4 from below wrap conductive metallic adhesive tape around
Motor temperature cable
conductive metallic adhes
ive
tape
Motor cable
Figure 31: Tape shield motor temperature cable around
NOTE!
The shielding of the motor temperature cable and the shielding of the motor cable is
wrapped together with a conductive metallic adhesive tape.
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Installation
5 connect both shielding with shield clamp on the shield sheet,
note locking torque of th
NOTE!
The shield must
tional shield sheet is not used!
Shield sheet
be connected to the mounting plate with a metallic clamp, if the op-
e fixing screw!
7
Motor temperature cable
Fixing
screw
Shielding
clamp
Motor cable
Figure 32: Shield connection motor cable
Wrapping with
met
allic adhe-
sive tape
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7.9
Requirements for the motor temperature sensors
Locking torque of the fixing screw:
Axis module 1 / 2 / 3
BM5807-SG
-22XXXX-,
-23XXXX-,
-24XXXX-,
-25XXXX-,
-26XXXX-,
-27XXXX-,
-28XXXX-
-31XXXX-,
-32XXXX-,
-33XXXX-
Locking torque
0.8 Nm
cable diameter 5 - 20 mm
shielding clamp width 24 mm
cable diameter 5 - 28 mm
shielding clamp width 31 mm
7.9 Requirements for the motor temperature sensors
To protect the motor against impermissible ove
be connected to the b maXX device. The device switches off of the motor when a settable
threshold temperature has been exceeded.
Type Additional requirements: Isolation
rheating, a motor temperature sensor can
1 Nm
KTY84 - SELV/PELV
PT1000 - SELV/PELV
MSKL
1)
Motor protection thermistor (PTC) as per DIN 44080-082
NOTE!
The motor temperature sensor should be installed in such a manner that „electrically
protective separation“ is ensured. The motor temperature sensors integrated into
Baumüller motors meet these requirements. If third-party motors are connected, the
operating company must ensure that the temperature sensors used in the motor of a
third-party manufacturer motor comply with the „electrically protective separation“
function.
1)
(PTC) R = 1 k at T
Schutz
, I
< 2 mA SELV/PELV
max
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7.10 Installation procedure
DANGER!
isk of fatal injury from electrical current!
R
Electrically live parts are life-threatening.
Therefore:
m Make certain that the parts to be mounted (e.g. mains cables) and the mounting
areas are de-energized for the entire duration of mounting the device.
h Route all cables in an EMC-compatible manner.
h Conn
h Fo
ect cables (refer to ZConnection diagrams– from page 86).
(Observe the permissible torques!)
r all connections, attentions is to be paid to strain relief
Installation
7
The installation compris
1 Co
nnect the motor through terminals 1U2, 1V2, 1W2 and PE.
Ensure the proper phases when connecting (rotational direction).
Observe the permissible torques!
NOTICE!
The internal overload protection is activated at 200 % of the motor rated current (full
load current).
2 Connect the DC link,
refer to ZM
3 Con
4 Co
5 Co
nect the protective ground conductor to the PE terminal (a fixed ground conductor
connection is absolutely mandatory).
nnect 24 V power supply:
BM58XX v
X200 -1, X200 -2.
nnect encoders (refer to ZEncoder evaluation– from page 96).
NOTE!
Plugging in and pulling out encoder cables while they are energized is prohibited, and
could lead to encoder destruction.
Therefore, always first switch off the 24 V supply voltage and lock the plug connectors
in place.
ounting of the DC link bar– on page 69.
ia terminals
es the following steps:
6 Connect the temperature sensor of the motor. (Observe the proper polarity!)
7 Co
nnect the motor brake: (option)
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7.11
Fieldbus IN
Fieldbus OUT
DC link connection
to mains inverter
or further
Axis module 1
(single oder
double axis)
Axis module 2
(single oder
double axis)
Axis module 3
(single oder
double axis)
Option:
digital
inputs
Option:
analog
outputs
multi-axis controller
Connection diagrams
7.11 Connection diagrams
NOTE!
e identifiers 1C1 and 1D1 were taken over from DIN EN 60445. 1C1 is the connec-
Th
tion to the positive DC link cable/bar, and in the past was identified by Baumüller in
some devices as ZK+. 1D1 is the connection to the negative DC link cable/bar, and
in the past was identified by Baumüller in some devices as ZK-.
7.11.1 Connection diagram overview
Figure 33: Connection diagram overview
1C1, 1D1 DC link connection, refer to ZFigure 36– on page 89.
X2 Option: connections for additional digital inputs
X3, X4 Connection fieldbus, depending on the configuration,
refer to type code ZType
X6 Option: connections for additional analog outputs
X200 Connections for 24 V voltage supply,
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refer to ZX
Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
200 (SELV/PELV)– on page 92.
code– on page 49
7.11.2 Connection diagram axis module -1 / -2 / -3 (single axis module)
Motor temperature
Motor brake
Encoder
not assigned
STO function
2 digital inputs
Motor
brake
Motor temperature
not assigned
Encoder
Installation
7
X1-1, X1-2, X1-3 Connection STO function, refer to ZOption: STO function– on page 94
X2-1, X2-2, X2-3 Connections for digital inputs, refer to ZF
X7-1, X7-2, X7-3 Encoder evaluation
X107-1, X107-2, X107-3 Motor connection
X207-1, X207-2, X207-3 Connection for motor temperature and motor brake,
Figure 34: Connection diagram axis module 1 / 2 / 3 (single axis module)
ast digital inputs– on page 95
refer to ZMo
tor temperature and motor brake– on page 102.
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7.11
Motor temperature 2
Motor brake 2
Encoder 1
Encoder 2
STO function
Motor
brake
Motor
brake
Motor temperature 1
Motor temperature 2
2 digital inputs
Motor temperature 1
Motor brake 1
Encoder
Encoder
Connection diagrams
7.11.3 Connection diagram axis module -1 / -2 / -3 (double axis module)
Figure 35: Connection diagram axis module 1 / 2 / 3 (double axis module)
X1-1, X1-2, X1-3 Connections STO function, refer to ZOption: STO function– on page 94
X2-1, X2-2, X2-3 Connections for digital inputs, refer to ZFast digital
X7-1, X7-2, X7-3 Encoder evaluation 1
inputs– on page 95
X8-1, X8-2, X8-3 Encoder evaluation 2
X107-1, X107-2, X107-3 Motor connection 1
X108-1, X108-2, X108-3 Motor connection 2
X207-1, X207-2, X207-3 Connections for motor temperature and motor brake for motor 1,
refer to ZM
X208-1, X208-2, X208-3 Connections for motor temperature and motor brake for motor 2,
refer to ZM
otor temperature and motor brake– on page 102
otor temperature and motor brake– on page 102
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7.11.4 Connections BM5800
DC link
Back side
X107-1
X108-1
X107-2
X108-2
X108-3
X107-3
Installation
7
Figure 36: Connections BM5800 top / bottom
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Option:
Additional
digital inputs
X2
X3
Fieldbus IN
X4
Fieldbus OUT
X6
Option:
Analog
outputs
X1-1
X1-2
X1-3
Option:
STO function
X2-1
X2-2
X2-3
Digital inputs
X7-1
X7-2
X7-3
Encoder 1
X8-1
X8-2
X8-3
Option
encoder 2
X207-1
X207-2
X207-3
Motor 1
Brake and temperature
X208-1
X208-2
X208-3
Motor 2
7.11
Connection diagrams
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Figure 37: Connections BM5800 front
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7.11.5 Connection data
NOTE!
To ensure sufficient current load capacity of the connections, adhere to the specified
torques!
Connections
on top/on bottom
Installation
7
Connection
cross section
PE device Min. 10 mm² Cable lug for M5 Min. 2.2 Nm
DC link
1C1 and 1D1
Motor
X107-1/-2/-3
Motor 1
X108-1/-2/-3
Motor 2
1U2, 1V2, 1W2
-22XXXX-
-23XXXX-
-24XXXX-
-25XXXX-
-26XXXX-
-31XXXX-
-27XXXX-
-32XXXX-
-28XXXX-
-33XXXX-
Connection
cross section
at rated power/
connection
Min. 0.75 mm²
Min. 2.5 mm²
Min. 4 mm²
Min. 6 mm²
DC link bar Min. 2.2 Nm
a)
a)
a)
a)
Connection
method
Connection
cross section
terminal
Max. 2.5 mm²
Min. 2,5 mm²
Max. 6 mm²
a)
a)
a)
Torque Load capacity
Max. 3.0 Nm
Torque Max load
Max. 3.0 Nm
Connec-
tion
method
Plug
connector,
threaded
connector
Plug
connector,
spring-
clamp con-
nection
Min. 0.4 Nm
Max. 0.5 Nm
-
capacity of the bar
130 A
Torque Load
capacity
Limited by
the device.
Refer to also
ZElectrical
-
data– from
page 36
a)
With or without wire end ferrule
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7.11
Connection diagrams
Connection cross section Connection
method
Motor PE Refer to motor cable Cable lug
fo
r M4
Connection
method
Plug connector,
spring-clamp con-
nection
Connection
method
X200 (SEL
24 V voltage supply
Connections on
the front side
V/PELV)
Connection
ss section
cro
Max. 1,5 mm²
(2-wire, 2-pin)
Refer to ZRequirements for control voltage / 24 V power supply– on page 30.
Connection
cross section
Torque Load
capacity
Min. 1.4 Nm
Max. 1.8 Nm
Load capacity
Max. 16.0 A
Load capacity
Refer to
ZElectrical
data– from
page 36
X1-1/-2/-3 (SEL
STO function,
refer to ZO
from page 94
X2-1/-2/-3 (SEL
Fast digital inputs,
refer to ZFast digital
from page 95
X7-1/-2/-3 (SEL
Encoder 1,
refer to ZEncode
from page 96
X8-1/-2/-3 (SEL
Encoder 2
refer to ZEncode
from page 96
V/PELV)
ption: STO function–
V/PELV)
V/PELV)
r evaluation–
V/PELV)
r evaluation–
inputs–
Max. 1.5 mm² Plug connector,
spring-clamp con-
nection
Max. 1.0 mm² Plug connector,
ring-clamp con-
sp
nection
D-sub
26-pin
D-sub
26-pin
Max. 8.0 A
Max. 8.0 A
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Installation
7
X207-1/-2/-3
Motor temperature and motor
brake motor 1
refer to ZMotor temperature
and motor brake– on page
102
X208-1/-2/-3
Motor temperature and motor
ake 2,
br
refer to ZMo
and motor brake– on
102
tor temperature
page
NOTE!
The input current of the 24 V power supply is limited to 16 A when using a BM5800
multi-axis controller. If several double axis modules with several brakes are used, the
maximum brake current of all integrated axis modules together is limited to 12 A.
Connection
cross section
Max. 1.5 mm² Plug connector,
Max. 1.5 mm² Plug connector,
Connection
method
spring-clamp
connection
ing-clamp
spr
connection
Load capacity
Max. 2 A
Max. 2 A
NOTE!
A relay with varistor protection circuit is required in case the customer connects an
additional relay.
X2
Option: Additional digital inputs
refer to ZOp
fast digital inputs– o
103
X3 /X4
Fieldbus IN / OUT
refer to ZFie
104
X6
Option: Analog outputs
refer to ZOp
puts– o
tion: Additional
n page
ldbus– on page
tion: Analog out-
n page 108
Connection
cross section
Max. 1.5 mm² Plug connector,
Connection
method
ing-clamp
spr
connection
Ethernet
nection
con
D-sub
9-pin
Load capacity
Max. 3.5 A
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7.11
1
7
8
14
7.11.6 Option: STO function
Connection diagrams
Axis module 1: X1-1 (SELV/PELV)
Axis module 2: X1-2 (SE
Axis module 3: X1-3 (SE
Digital input: Low
Max. reaction time Max. 30 ms
Pin assignment X1-1, X1-2, X1-3
Pin No. Assignment
LV/PELV)
LV/PELV)
volt
High
Voltage: 20 … 30 V
1 STO1 GND axis 1 of axis module 1 / 2 / 3
2 STO2 GND axis 1 of axis module 1 / 2 / 3
age: -0.3 … 5 V
3 Not assigned
4 STO1 GND axis 2 of axis module 1
5 STO2 GND axis 2 of axis module 1
6 Not assigned
7 STO1 24V axis 2 of axis module 1 / 2 / 3, double axis modules only
8 STO1 24V axis 1 of axis module 1 / 2 / 3
9 STO2 24V axis 1 of axis module 1 / 2 / 3
10 Not assigned
11 Reserved, internal connected with pin 7,
STO1 24V axis 2 of axis module 1 / 2 / 3, double axis modules only
12 STO2 24V axis 2 of axis module 1 / 2 / 3, double axis modules only
13 Not assigned
14 Reserved, internal connected with pin 8,
STO1 24V axis 1 of axis module 1 / 2 / 3
NOTE!
The used power supply must comply with the defined power supply interruption according EN60204-1.
/ 2 / 3, double axis modules only
/ 2 / 3, double axis modules only
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7.11.7 Fast digital inputs
1
4
Axis module 1: X2-1,
Axis module 2: X2-2,
Axis module 3: X2-3
Evaluation: Edge triggered, programmable
Input current per input: 20 mA fast digital input
Input delay: Max. 10 µs fast digital input
Level: Low (0 … 5 V);
Galvanic separation: Optocoupler
Short-circuit resistant Current limited
High (12 … 28 V)
Installation
7
Pin assignment X2-1, X2-2,
Pin No. Assignment
1 GND 24 V internal
2 GND digital inputs
3 Fast digital input 1 (touch probe 1)
4 Fast digital input 2 (touch probe 2)
NOTE!
Pin 1 and pin 2 can be connected if the device and the digital inputs are supplied by
the same or different power supplies with identical ground.
Pin 2 must be connected with the ground of the power supply of the digital inputs if it
has a different ground potential.
Pin 1 is the looped through ground of the device power supply.
X2-3
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7.11
7.11.8 Encoder evaluation
Connection diagrams
Axis module 1: X7-1, X8-1
Axis module 2: X7-2, X8-2
Axis module 3: X7-3, X8-3
Connector assignment depends on encoder selection.
Encoder cables refer to ZEncoder cables– from page 144.
Resolver
evaluation
All encoders, that comply with the following technical specification, may also be used:
Pole pair number The ratio between the pole pair number of the motor and
the pole pair number of the encoder must be an integer.
Current input Max. 160 mA
Excitation frequency Approx. 8 kHz
Excitation current 160 mA
Ratio 0.5
1 GND encoder supply / Ref -
2 Reserved *
3 Reserved *
4 Reserved *
5 Reserved *
6 Reserved *
7 Reserved *
8 Reserved *
9 Reserved *
10 Resolver Ref +
11 Reserved *
D-sub-connector
26-pin
12 Reserved *
13 Reserved *
14 Reserved *
15 Reserved *
16 Reserved *
17 Temperature +
18 Temperature -
19 Reserved *
20 Reserved *
21 Res A + (COS +)
22 Res A - (COS -)
23 Reserved *
24 Reserved *
25 Res B + (SIN +)
26 Res B - (SIN -)
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Installation
7
Encoder
evaluation
HIPERFACE
®
The encoder evaluation is provided with a HIPERFACE®-interface.
The encoders, which meet the following technical specifications, can be used:
Voltage supply 10 V
Signal level HIPERFACE® - specification of the process data
Current input Max. 250 mA
1 GND encoder supply
2 +10 V encoder supply
3 Reserved *
4 COS +
5 COS -
6 SIN +
7 SIN -
8 Reserved *
9 Reserved *
10 Reserved *
11 Reserved *
D-sub-connector
26-pin
12 Reserved *
13 Reserved *
14 Reserved *
15 Reserved *
16 Reserved *
17 Temperature +
18 Temperature -
19 RS485 Data +
20 RS485 Data -
21 Reserved *
22 Reserved *
23 Reserved *
24 Reserved *
25 Reserved *
26 Reserved *
DC
channel (~1 V
; REFSIN/REFCOS 2.5V)
SS
* Do not occupy
Instruction handbook b maXX 5800
Document No. 5.16027.04
97
of 174
7.11
Connection diagrams
Encoder evaluation with
EnDat® 2.1 or SSI
The encoders, which meet the following technical specifications, can be used:
Voltage supply 5 VDC controlled
Signal level ~1 V
Current input Max. 250 mA
1 GND encoder supply
2 +5 V encoder supply
3 Clock+
4 A + (COS +)
5 A - (COS -)
6 B + (SIN +)
7 B - (SIN -)
8 Reserved *
9 Reserved *
10 Reserved *
11 Sense GND
D-sub-connector
26-pin
12 Sense Vcc
13 Clock-
14 Reserved *
15 Reserved *
16 Reserved *
17 Temperature +
18 Temperature -
19 Data +
20 Data -
21 Reserved *
22 Reserved *
23 Reserved *
24 Reserved *
25 Reserved *
26 Reserved *
SS
98
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* Do not occupy
Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
Installation
7
Encoder
evaluation with
®
EnDat
2.2
The encoders, which meet the following technical specifications, can be used:
Voltage supply 5 VDC controlled
Signal level ~1 V
Current input Max. 250 mA
1 GND encoder supply
2 +5 V encoder supply
3 Clock+
4 Reserved *
5 Reserved *
6 Reserved *
7 Reserved *
8 Reserved *
9 Reserved *
10 Reserved *
11 Sense GND
D-sub-connector
26-pin
12 Sense Vcc
13 Clock-
14 Reserved *
15 Reserved *
16 Reserved *
17 Reserved *
18 Reserved *
19 Data +
20 Data -
21 Reserved *
22 Reserved *
23 Reserved *
24 Reserved *
25 Reserved *
26 Reserved *
SS
* Do not occupy
Instruction handbook b maXX 5800
Document No. 5.16027.04
99
of 174
7.11
Connection diagrams
Sine or square
wave encoder
evaluation
The encoders, which meet the following technical specifications, can be used:
Voltage supply 5 VDC controlled
Signal level RS422 (TTL) for square wave incremental encoders
~1 Vss for sine incremental encoders
Current input Max. 250 mA
1 GND encoder supply
2 +5 V encoder supply
3 Reserved *
4 RS422 A +
5 RS422 A -
6 RS422 B +
7 RS422 B -
8 RS422 0 +
9 RS422 0 -
10 Reserved *
11 Sense GND
D-sub-connector
26-pin
12 Sense V
13 Reserved *
14 Reserved *
15 Reserved *
16 Reserved *
17 Temperature +
18 Temperature -
19 Reserved *
20 Reserved *
21 Reserved *
22 Reserved *
21 Reserved *
22 Reserved *
23 Reserved *
24 Reserved *
25 Reserved *
26 Reserved *
CC
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Instruction handbook b maXX 5800
Document No. 5.16027.04 Baumüller Nürnberg GmbH
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