b maXX 5000
Table of contents
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Instruction handbook
Language English
Translation
Document No. 5.09021.17
Part No. 439683
Status 22-May-2019
E
5.09021.17
b maXX 5000
BM5000, BM5100
Mains rectifier/
Active mains rectifier
BM5300
Axis units safety
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
Email : mail@baumueller.de
Internet: www.baumueller.de
Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Information on the instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.10 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.11 List of other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Contents of the Instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Usage for the intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Risk assessment according EU Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.7 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.8 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.9 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.12 Conduct in case of danger or accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.13 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.1 BM503X dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.2 BM504X dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.3 BM517X dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.4 BM519X dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.5 BM53XX dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.1 Requirements for power supply / mains supply system . . . . . . . . . . . . . . . . . . . . . . 44
3.3.2 Requirements for control voltage / 24 V power supply . . . . . . . . . . . . . . . . . . . . . . . 45
3.3.3 Requirements for the motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.4 Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.5 Correction values at changed operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3.5.1 Correction values for the output current of the mains inverter BM50XX, BM51XX . 49
3.3.5.2 Correction values for the output current of the axis units BM53XX . . . . . . . . . . . . . 50
3.3.5.3 Correction values input voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3.5.4 Correction values DC link voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.6 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.4.1 Electrical data BM50XX; BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.4.2 Electrical data of the BM53XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4.3 Output frequency-dependent current derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.4.4 Load cycle according EN61800-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4.5 Proposal for dimensioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.2 Identification of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2.1 Part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2.3 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3 UL notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.4 Display and operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.4.1 LED display BM5XXX-XX0X-... without safety function. . . . . . . . . . . . . . . . . . . . . . . 90
4.4.2 Display and operating elements BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.4.2.1 7-segment display BM51XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.4.2.2 LED display BM51XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.4.3 Display and operating elements BM53XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4.3.1 7-segment display controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4.3.2 LED display controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.4.4 LED display fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.4.5 Setting the IP address with address switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.3 Transport inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.5 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.2 Preparing for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.2.1 Drilling pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.2.2 Mechanical data of the mounting plate for cold plate. . . . . . . . . . . . . . . . . . . . . . . . 112
6.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.3.1 Mounting with mounting rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.3.2 Mounting without mounting rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.3.3 Mounting of the DC link bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.3.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.3.5 Special DC link connection BM519X, BM537X . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4 Mounting of toroidal cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.4.1 Drilling pattern toroidal cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.4.2 Mounting the toroidal cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.4.3 Connecting the water cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.2 Voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.3 Demands on the electrical mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.3.1 Connection notes: IT-system or grounded phase conductor system with BM50XX 127
7.4 Requirements for the connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.5 Protection of the device and the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.6 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.7 Grounding concept of the side-by-side mounted system . . . . . . . . . . . . . . . . . . . . . . 130
7.8 Installation requirements with regard to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.9 Shielding plan side-by-side mounted system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.9.1 Shielding connection mounting plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.9.2 Shielding connection with shield sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.9.2.1 Mounting shield sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.9.2.2 Connecting the shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.10 Avoid bearing currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.11 Requirements for the motor temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.12 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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7.13 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.13.1 Connection diagram of BM50XX-XX0X-... mains rectifier without safety function. . 143
7.13.2 Connection diagram for the BM51XX active mains rectifier unit . . . . . . . . . . . . . . . 145
7.13.2.1 Connection proposal BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.13.2.2 Connection proposal BM51XX pulse enable control . . . . . . . . . . . . . . . . . . . . . . . 148
7.13.2.3 Timing diagram for switching on BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.13.3 Connection diagram single axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.13.3.1 Connection diagram BM5326, BM5327, BM5328 . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.13.3.2 Connection diagram BM5334, BM5335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.13.3.3 Connection diagram BM537X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.13.4 Connection diagram for the double axis unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.13.4.1 Connection diagram BM5323, BM5325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.13.4.2 Connection diagram BM5331, BM5332, BM5333 . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.14 Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.14.1 Electrical connections of the BM50XX-XX0X-... without safety function . . . . . . . . . 157
7.14.2 Electrical connections of the BM51XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.14.3 BM519X connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.14.4 Electrical connections of the single axis BM5326, BM5327, BM5328. . . . . . . . . . . 160
7.14.5 Electrical connections of the single axis BM5334, BM5335 . . . . . . . . . . . . . . . . . . 161
7.14.6 Electrical connections of the single axis BM537X . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.14.7 Electrical connections of the double axis BM5323, BM5325. . . . . . . . . . . . . . . . . . 164
7.14.8 Electrical connections of the double axis BM5331, BM5332, BM5333 . . . . . . . . . . 165
7.14.9 Connection data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.15 Connections on the front side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
7.15.1 Front side of mains rectifier unit BM50XX-XX0X-... without safety function . . . . . . 171
7.15.2 Front side of active mains rectifier BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.15.3 Front side axis units BM53XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8.1 Operating concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.1.1 Release signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.1.2 Service interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.2 Timing diagrams BM50XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.3 Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.3.1 Monitoring BM50XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.3.2 Monitoring BM51XX, BM53XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.4 Fieldbus communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.4.1 EtherCAT®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.4.2 VARAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
8.4.3 CANopen®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.4.4 POWERLINK®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
9.1 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.2 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.3 Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10 Troubleshooting and Fault correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.2 Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
10.2.1 Monitoring function - explanations BM50XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.2.2 Monitoring function - explanations BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
10.2.3 Monitoring function - explanations BM53XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10.3 Error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.3.1 BM50XX error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.3.2 BM51XX and BM53XX error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.4 Error handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.4.1 Error acknowledgment of BM50XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.4.2 Error acknowledgment of BM51XX and BM53XX . . . . . . . . . . . . . . . . . . . . . . . . . . 239
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11 Accessories and spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
11.1 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
11.1.1 Device - mains cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
11.1.2 Cable device - motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
11.1.3 Hybrid cable device-encoder-motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
11.1.4 Control voltage supply/signal cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
11.1.5 Signal bus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
11.1.6 EtherCAT®, VARAN, POWERLINK® cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
11.1.7 Accessories - CANopen®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
11.1.8 Service interface cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
11.1.9 Encoder cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
11.1.9.1 Connecting cable for Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
11.1.9.2 Connecting cable for encoder with HIPERFACE® . . . . . . . . . . . . . . . . . . . . . . . . . 254
11.1.9.3 Connecting cable for encoder with EnDat® or SSI. . . . . . . . . . . . . . . . . . . . . . . . . 255
11.1.9.4 Connecting cable for encoder with EnDat® 2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11.1.9.5 Connecting cable for sine/square-wave incremental encoder . . . . . . . . . . . . . . . . 258
11.1.10 Connection cable add-on modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
11.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
11.2.1 BM5030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
11.2.2 BM5031, BM5032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
11.2.3 BM5043, BM5044 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
11.2.4 BM5173, BM5174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
11.2.5 BM5192, BM5193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
11.3 Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
11.3.1 Fixed tube resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
11.3.2 Fixed frame resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
11.4 Line filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
11.4.1 Baumüller mains filter type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
11.4.2 Selection of the mains filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.5 Power chokes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
11.5.1 Power choke BM50XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
11.5.2 Power chokes for BM51XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
11.6 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
11.6.1 Plug connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
11.6.2 Accessories kit shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
11.7 Connection rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
11.8 Toroidal cores. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
12 Shutdown, Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
12.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
12.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
12.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
12.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
12.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
12.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
13 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
13.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
13.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
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Table of Contents
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Appendix B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Appendix C - BM5030 with Safety Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
C.1 Approvals, directives and standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
C.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
C.3 Electrical data BM5030 with safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
C.4 LED display BM5030 with safety function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
C.5 Connection diagram BM5030 with safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
C.6 Electrical connections BM5030 with safety function . . . . . . . . . . . . . . . . . . . . . . . . . . 310
C.6.1 Connection data of BM5030 with safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
C.6.2 Connections front side BM5030 with safety function . . . . . . . . . . . . . . . . . . . . . . . . 313
C.7 Description of the safety function STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
C.7.1 Safety related characteristics of the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . 317
C.7.2 Reaction time STO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
C.7.3 Cycle time STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
C.7.4 Safety function STO im BM5030-XX2X-... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Overview of Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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Instruction handbook b maXX 5000
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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 a
structions.
Additionally, the valid accident prevention reg
plicable to the scope of application th
Read the instruction handbook, particularly th
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
1GENERAL
ll specified safety notes and procedural in-
ulations and general safety regulations ap-
e device must be complied with.
e safety notes chapter, completely before
Warning notes are identified by symbols in these
troduced by signal words that express the extent of the danger.
It is imperative that these notes be complied with and are conscientiously regarded in order to prevent accidents, personal injury and material damage.
DANGER!
....points out an immediately dangerous
death if not avoided.
WARNING!
....points out a potentially dangerous situation that could lead to severe injuries or
death if not avoided.
Instruction handbook b maXX 5000
instruction handbook. The notes are in-
situation that will lead to severe injuries or
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9
1.3
Recommendations
Limitation of liability
CAUTION!
....points out a potentially dangerous situation
ries if not avoided.
NOTICE!
....points out a potentially dangerous situation that could lead to material damage if
not avoided.
that could lead to minor or slight inju-
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 regulation
and experience of many years.
The manufacturer ass
m n
on-compliance with the instruction handbook
m u
sage for other than the intended purpose
m usa
ge by untrained personnel
The actual scope of delivery can vary in case
tional order options, or on account of the latest te
representations described herein.
The user bears the responsibility for performing service and initial operation in
dance with the safety regulations of the applicab
ernmental or local regulations concerning the dim
grounding, disconnectors, overcurrent protection, etc.
The person who carried out the mounting or installation is liable for any damage incurred
en assembling or connecting the device.
wh
s, the state of the art and our knowledge
umes no liability for damages due to:
of optional equipment, laying claim to addi-
chnical changes to the explanations and
accor-
le standards and all other relevant gov-
ensioning and protection of conductors,
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Instruction handbook b maXX 5000
Document No.: 5.09021.16 Baumüller Nürnberg GmbH
1.4 Copyright protection
The instruction handbook must be treated confidentially. It is to be used exclusively by
personnel who work with the device. The consignment of the instruction handbook to third
persons without the written permission of the manufacturer is prohibited.
NOTE!
The specific contents, text, drawings, images and other representations are copyrighted and subject to industrial property righ
by law.
General
ts. Any prohibited usage is punishable
1
CANopen
EnDat
EtherCAT
HIPERFACE
HIPERFACE DSL
PROFINET
speedtec
NOTE!
Please note, that BAUMÜLLER is not responsib
property) rights of third parties are infringed by the application-specific use of the
BAUMÜLLER products/components or the execution.
®
®
®
®
®
is a registered trademark of PROFIBUS International
®
1.5 Other applicable documents
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 Produkt GmbH
94559 Niederwinkling, Germany
le to examine whether any (industrial
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 th
Instruction handbook b maXX 5000
e respective manufacturers.
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1.6
Spare parts
1.6 Spare parts
WARNING!
False or flawed spare parts can lead to damage, malfunction or complete fail-
ure, thus endangering safety.
Therefore:
m Only
use original spare parts of the manufacturer.
Procure spare parts through an authorized deale
Refer to ZAc
1.7 Disposal
Insofar as no take-back or disposal agreement has been made, please disassemble units
correctly and properly recycle the constituent parts.
Refer to ZDisp
1.8 Guarantee provisions
The guarantee provisions are stated in a separate document of the sales documents.
The devices described herein may only be ope
methods, procedures and conditions. Anything else not presented here, including the operation of devices in mounted positions, is no
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
r or directly from the manufacturer.
cessories and spare parts– as from page 241.
osal– on page 293.
rated in accordance with the stipulated
t permitted and must be cleared with the
1.10 Terms used
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Document No.: 5.09021.16 Baumüller Nürnberg GmbH
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
he Internet.
t
The term „device“ or the item designation BM5XXX are also used in this documentation
for the Baumüller product „b maXX 50
in ZAppe
ndix A - Abbreviations– as from page 297.
00“. A list of the abbreviations used can be found
1.11 List of other applicable documents
General
1
Instruction
handbook
Parameter manual
Instruction
handbook safety
les
modu
Instruction
handbook add-on
les
modu
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
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 5000
Document No.: 5.09021.16
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1.11
List of other applicable documents
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Instruction handbook b maXX 5000
Document No.: 5.09021.16 Baumüller Nürnberg GmbH
This section provides an overview of all of the important safety aspects for optimum protection of personnel as well as for the safe and problem-free operation.
2.1 Contents of the Instruction handbook
Each person who is tasked with performing work on or with the device must have read
and understood the instruction handbook before working with the device. This also ap
plies 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.
2.3 Usage for the intended purpose
2SAFETY
-
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 with servo controller or decentralized drive solu
tions BM2500. Devices are also available in graduated design size and performance
classes.
The device b maXX 5000 is used exclusively as a converter for controlling a motor.
A device is considered as being used compliant with its intended purpose if all notes and
information of these instruction handbook are adhered to.
Instruction handbook b maXX 5000
Document No.: 5.09021.16
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-
2.3
Usage for the intended purpose
WARNING!
Danger arising from usage for an unintended purpose!
Any usage that goes beyond the intended purpose and/or any non-compliant use of
e device can lead to dangerous situations.
th
Therefore:
m Only
m Obser
m En
m Whe
m M
m T
m Ens
m T
m Only op
m The dev
m T
use the device compliant with its intended purpose.
ve all specifications of these instruction handbook.
sure that only qualified personnel work with/on this device.
n configuring, ensure that the device is always operated within its specifica-
tions.
ount the device on a wall that can sufficiently bear the load.
he device must always be operated within a control cabinet.
ure that the power supply complies with the stipulated specifications.
he device may only be operated in a technically flawless condition.
erate the device in combination with components approved by Baumüller
Nürnberg GmbH.
ice has been developed in such a manner that it fulfills the requirements
of the category C3 according to IEC 61800-3:2012.
he device is not intended to be connected to the public mains. To operate the device in primary surroundings of the catego
mercial areas, directly on a pu
transformer), special measures to reduce the transient emissions (line-internal and
radiated) must be provided for and certifiable by the system builder. Otherwise,
EMC interference could occur without such additional measures.
ry C2/C1 (residential, business and com-
blic low-voltage mains without an intermediate
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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!
Instruction handbook b maXX 5000
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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
r cables
powe
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 sh
n The co
must be laid without loop.
nnection between power supply and device or between device and motor
ort-circuit in power cables,
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 5000
Document No.: 5.09021.16 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 in
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
struction handbook, the safety, accident
essment, any additional hazards that could
2
2.6 Protective devices
BM50XX IP 20
BM517X IP 20, with a contact-isolated con-
BM519X IP 00
BM5323, BM5325 IP 20
BM5326, BM5327, BM5328,
BM5331, BM5332, BM5333
BM5334, BM5335 IP 20, with a contact-isolated con-
BM537X IP 00
IP code
nection in accordance with IP 20,
ot
herwise IP 10.
IP 10
nection in accordance with IP 20,
ot
herwise IP 10.
DANGER!
Risk of fatal injury from elec
There is an immediate risk of fatal injury if live electrical parts are contacted.
Therefore:
device must be in operated inside of a control cabinet that provides protection
m The
against direct contact of the devices and at least meets the requirements of
EN 61800-5-1, Chapter 4.2.3.3.
trical current!
Instruction handbook b maXX 5000
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2.7
Training of the personnel
2.7 Training of the personnel
WARNING!
Risk of injury due to insufficient qual
Improper handling can lead to significant personal injury and material damage.
Therefore:
tain activities can only be performed by the persons stated in the respective
m Cer
chapters of these instruction handbook.
In these instruction handbook, the following qualifications are stipulated for various areas
tivity:
of ac
ifications!
m Oper
m Qualified
ating personnel
n The d
n Tro
n Initial operation
n Ele
n Qua
rive system may only be operated by persons who have been specially trained,
familiarized and authorized.
ubleshooting, 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.
and familiarization may only be performed by qualified personnel.
personnel
ctrical engineers authorized by Baumüller Nürnberg GmbH, and qualified electri-
cians of the customer or a third party who have learned to install and maintain
umüller drive systems and are authorized to ground and identify electrical power
Ba
circuits and devices in accordance with the safety engineering standards of the company.
lified 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.
e protective equipment necessary for each respective type of work shall always be
m Th
worn during work.
e personal safety signs present in each working area must be observed.
m Th
Protective work clothing
should be snug-fitting work clothes, with
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
low tearing resistance, narrow sleeves and
2
Wear for special
rk.
wo
Safety shoes
to protect against heavy objects falling
Protective gloves
to protect hands against friction, abrasion, punctur
as contact with hot objects.
Protective eye wear
to protect the eyes against flying around objects and sprayed liquids.
down.
ing or more severe injuries, as well
Instruction handbook b maXX 5000
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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
Observe the safety notes listed here and the warning notes in the further chapters of this
truction handbook to reduce health risks and dangerous situations.
Ins
Electrical current
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live
to the insulation or individual components can be life-threatening.
Therefore:
m Switch
m Only
m Switch
analysis.
electrical parts are contacted. Damage
off the electrical power immediately in case of damage to the power supply
insulation.
allow work on the electrical system to be performed by qualified personnel.
off the current when any kind of work is being performed on the electrical
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
link discharge time in the rack system.
Refer to ZElec
Therefore:
m Do no
the capacitors.
y attention to the corresponding notes on the device.
m Pa
m If ad
ditional 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.
trical data– as from page 58.
t touch electrically live parts before taking into account the discharge time of
of the device with the longest DC
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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:
not touch moving components during operation.
m Do
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-c
is used.
Therefore:
the following fire-extinguishing agent:
m Use
ABC powder / CO
2
onductive, fire-extinguishing agent
Instruction handbook b maXX 5000
Document No.: 5.09021.16
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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 highes
equipment makes work processes more awkward, under no circumstances may they
be circumvented. Safety can only be ensured by intact safety equipment.
Therefore:
fore starting to work, check whether the safety equipment in good working order
m Be
and properly installed.
2.12 Conduct in case of danger or accidents
t level of safety in a facility. Even if safety
Preventive
measures
And if something
happen:
does
respond properly.
m Always be prepared for accidents or fire!
m Keep first-aid equipment (e.g. firs
accessible.
m Familiarize personnel
m Stop operation of the device immediately with an EMERGENCY Stop.
m In
itiate first aid measures.
m Evacu
m No
m Ala
m Keep ac
ate persons from the danger zone.
tify the responsible persons at the scene of operations.
rm medical personnel and/or the fire department.
cess routes clear for rescue vehicles.
with accident alarm, first aid and rescue equipment.
t-aid kits, blankets, etc.) and fire extinguishers readily
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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 t
Over the course of time, stickers and symbols o
erwise unrecognizable.
Therefore:
m Main
condition.
Safety
o illegible symbols!
n the device can become dirty or oth-
tain all safety, warning and operating labels on the device in easily readable
2
Electrical voltage
Only qualified personnel may work in work areas that identified with this sign.
Unauthorized persons may not touch working ma
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the rack system = discharge t
link discharge time in the rack system.
Refer to ZElectrical da
Therefore:
o not touch before taking into account the discharge time of the capacitors and
m D
electrically live parts.
ed corresponding notes on the equipment.
m He
m If ad
ditional 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.
ta– as from page 58.
terials marked correspondingly.
ime of the device with the longest DC
Instruction handbook b maXX 5000
Document No.: 5.09021.16
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2.13
Signs and labels
CAUTION!
Risk of injury due to hot surface!
When in operation, the top o
Therefore:
m Wea
r protective gloves
f the device can heat up to temperatures > 70 °C!
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Figure 2: Signs and labels BM5XXX
Instruction handbook b maXX 5000
Document No.: 5.09021.16 Baumüller Nürnberg GmbH
Signs and labels
devices
with safety level
NOTE!
Safety
2
Only a device with built in Safety Module S
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.
AF XXX, marked with the TÜV Rheinland
Instruction handbook b maXX 5000
Document No.: 5.09021.16
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2.13
Signs and labels
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3.1 Dimensions
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 in ZD
as from page 111.
3.1.1 BM503X dimensions
3TECHNICAL DATA
rilling pattern–
Figure 3: BM503X-C/-S dimensions
*: Observe minimum clearance.
Please follow the notes for mounting and
g– on page 56.
ZCoolin
Instruction handbook b maXX 5000
Document No.: 5.09021.16
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395
373
357,5
100 *
100 *
75
210
BM503X-A
READY
H1
H2
H3
H4
PHASEFAILURE
OVERTEMPERATURE
DC-LINKERROR
b maXX
5000
309 26
68
3.1
Dimensions
Figure 4: BM503X-A dimensions
*: Observe minimum clearance.
Please follow the notes for mounting and ZCooling– on
page 56.
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