Baumuller b maXX BM1000 User manual

E5.07003.04
Manual
b maXX®BM1000
Basic unit

Title Manual
Product b maXX®BM1000
Version 5.07003.04
Part No. 410406
Status 29.02.2008
Copyright These operating instructions may be copied by the owner
in any quantity but only for internal use. For other purposes
these operating instructions and extracts thereof must not
be copied or reproduced.
Use and disclosure of information contained in these oper-
ating instructions are not permitted.
Designations and company marks contained in these op-
erating instructions may be brand names, the use of which
by third parties for their own purposes may violate the
rights of the holders.
Obligatory Theseoperatinginstructionsarepartofthe equipment/ma-
chine. These operating instructions must be available to
the operator at all times and must be in a legible condition.
If the equipment/machine is sold or moved to a different lo-
cation these operating instructions 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 of use this original and all copies must be
destroyed.
When the present operating instructions are handed over,
corresponding sets of operating instructions of a previous
version are automatically invalidated. Please notice that
specifications/data/information are current values ac-
cording to the printing date. These statements are not
legally binding according to the measurement, computa-
tion and calculations.
Baumüller Nürnberg GmbH reserves the right, in develop-
ing its products further, to change the technical specifica-
tions and the handling of the products concerned without
prior notice.
No liability can be accepted concerning the correctness of
the operating instructions unless otherwise specified in the
General Conditions of Sale and Delivery.
Manufacturer Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
D-90482 Nürnberg
Germany
Tel. [phone] - 0 Fax: [phone] - 1 30
www.baumueller.de

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Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Survey of the appliance series b maXX®BM1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 First steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Copyright and trade mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Fundamental safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Hazard information and commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Hazard information structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2 Form of the hazard sign (triangular or round) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2.1 Hazard information on personal injury. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.2.2 Hazard information on property damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2.3 Command signs used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Information sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Legal instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Inappropriate use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Training of the personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Safety precautions in normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.10 Dangers due to residual energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.11 Disposal of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.12 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.13 Responsibility and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.13.1 Observing the safety notes and safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.13.2 Dangers when handling this device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.13.3 Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Transportation and packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 To be considered by transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Dispose packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Description of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Interconnect the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Overview of dangerous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 Marking of the device - type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Preparation for installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5.1 Remove keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5.2 Remove front cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5.3 Remove main terminal cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5.4 Remove motor terminal cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5.5 Remove fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

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5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3 Prepare mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4 Installation space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.4.1 Installation space frame 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.4.2 Installation space frame 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4.3 Installation with metal separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4.4 Installation without metal separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Requirements to the electrical mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 Requirements to the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5 Protection of the device and of the cable respectively. . . . . . . . . . . . . . . . . . . . . . . . . 45
6.6 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.7 Requirements on the laying (EMC notes device). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.8 Operating sequence of installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.9 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.10 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.10.1 Specifications of main circuit terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.10.2 Connecting main terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.10.3 Mains power terminals (R/L1, S/L2, T/L3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.10.4 Output terminals (U/T1, V/T2, W/T3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.10.5 Terminals [+/B1, B2] for connecting chopper unit / braking resistor . . . . . . . . . . . . . 60
6.10.6 Grounding terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.11 Control Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.11.1 Specification of control terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.11.2 Terminal symbols and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.11.3 Analog input terminals (AVI, ACI, ACM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.11.4 Multi-function-inputs (MI1 to MI6, DCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.11.5 Multi-function output (MO1, MCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.12 External parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.13 RFI jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.14 Connect the DC link of the devices in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.15 Applications for mains chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.3 LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.4 Digital keypad (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.5 Preparations before commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.6 Commissioning example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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8 Error detection and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3 Error information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.1 Fault code information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.4 Warning code information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.5 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.6.1 Overcurrent (OC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.6.2 Ground fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.6.3 Overvoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.6.4 Low voltage (Lv) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.6.5 Overheat (OH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.6.6 Overload OL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.6.7 Keypad display is abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.6.8 Phase Loss (PHL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.6.9 Motor doesn’t run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.6.10 Motor speed cannot be changed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.6.11 Motor stalls during acceleration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.6.12 The motor does not run as expected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.7 Electromagnetic/induction noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.8 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.9 Affecting other machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.2 Environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.3 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.3.1 periodical maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
11 Shutdown, storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
11.3 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
11.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
11.5 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
11.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
12.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
12.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
12.3 Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12.3.1 Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
12.4 Recycling plants/offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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Appendix A - Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Appendix B - Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
B.1 Chopper units and braking resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
B.1.1 Select a chopper unit /braking resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
B.1.2 Chopper units BM1-BTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
B.1.3 Dimensions and weights for braking resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
B.2 Mains filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
B.3 Chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
B.3.1 Mains chokes recommended values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
B.3.2 Output chokes recommended values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
B.4 Fuses for device-protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
B.5 Non-fuse circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
B.6 Digital keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
B.7 Digital keypad cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
B.8 DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
B.8.1 BM1-MPL-01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
B.8.2 BM1-MPL-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
B.8.3 BM1-EPL-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
B.9 Accessories CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Appendix C -
Declaration of Conformity/Manufacturer, UL - Certification. . . . . . . . . . . . . . . . . . . . . . . . . . 137
C.1 What is an EU directive?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
C.2 What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
C.3 Definition of the term Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
C.4 Definition of the term Manufacturer’s Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
C.5 UL-certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Appendix D - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
D.1 Required environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
D.2 Non-electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
D.3 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
D.4 General specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
D.5 Fuse protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
D.5.1 Cable protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
D.5.2 Cable protection + device protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
D.6 Type of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
D.7 Fire fighting appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Appendix E - CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
E.1 Interface assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
E.2 Terminating plug for CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
E.3 Connection cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
E.4 Input wiring before using CANopen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
E.5 Setting of address and baudrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
E.5.1 Setting via software parameters P0870 and P0871 . . . . . . . . . . . . . . . . . . . . . . . . . 151
E.5.2 Setting of address via DIP switch without multiplier . . . . . . . . . . . . . . . . . . . . . . . . . 152
E.5.3 Setting of address via DIP switch with multiplier. . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E.6 CANopen display functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
E.6.1 LED display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
E.6.2 CANopen error display via digital keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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Table of contents
Appendix F - How to select the right b maXX®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
F.1 Capacity formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
F.2 General precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
F.3 How to choose a suitable motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
F.3.1 Standard motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
F.3.2 Special motors:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
F.4 Power Transmission Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
F.5 Motor torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Table of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Revision survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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Manual b maXX®BM1000
Document No. 5.07003.04
1INTRODUCTION
This manual is an important part of your b maXX®BM1000 appliance. Therefore please
read this manual completely, before starting any operation, last but not least on behalf of
your own security.
In this chapter we describe the first steps, which have to be done after you have received
the device. Terms are defined, which are continuously used in this manual. We will inform
you about duties, which must be considered when using this device.
1.1 Survey of the appliance series b maXX®BM1000
This manual is to be used for the installation, parameter setting, troubleshooting, and dai-
ly maintenance of theBaumüller device ’b maXX®BM1000’. To guarantee safe operation
of the equipment, read the safety guidelines before connecting power to the bmaXX®
BM1000. Keep this operating manual at hand and distribute to all users for reference.
1.2 First steps
hCheck delivery, see ZTransportation and packing– from page 23.
hProvide for qualified personnel for the mounting, installation and commissioning.
hHand over this manual to the personnel for mounting, installation and commissioning.
Assure that especially the safety instructions are understood and obeyed.
WARNING
The following may occur, if you disregard these safety notes:
mserious personal injury mdeath
All persons, who work on and with devices of the series b maXX®, must have this manual
available at their work place and must obey the instructions and notes contained therein - es-
pecially the safety instructions.

Used terms
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1.3
1.3 Used terms
In this manual we will also use the term ’device’ for the Baumüller product ’b maXX®’. A
list of the abbreviations which are used are to be found in ZAppendix A - Abbreviations–
from page 117.
1.4 Copyright and trade mark
b maXX®is a registered trade mark of Baumüller Nürnberg GmbH

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Manual b maXX®BM1000
Document No. 5.07003.04
2FUNDAMENTAL SAFETY
INSTRUCTIONS
2.1 General notes
In this chapter dangers are described, arising when working with the Baumüller-device.
Dangers are pointedup with symbols (icons). All symbols that are used in this manual are
listed and explained.
How you can protect yourself against the single dangers in the concrete case, we will not
explain in this chapter. This chapter contains only general protective measures. The con-
crete protective measures we will always give directly after the note to the danger.
The operation of the described devices is permissible, if the mentioned methods/proce-
dures/measures are obeyed to. Everything else, that means also the operation of devices
in installations, which are not shown here, is not permitted and must be checked with the
company in each particular case. Any kind of claim to warranty will expire, if the devices
are operated other than here described.
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
The hazard information is showing you the hazards which can lead to injury or even to
death.
Always observe the hazard information given in this documentation.

Hazard information and commands
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2.2
2.2 Hazard information and commands
Each hazard is classified in one of three different hazard classes. Every hazard class
has one of the following characteristic signal words:
DANGER
mserious property damage mserious personal injury mdeath - will occur
WARNING
mserious property damage mserious personal injury mdeath - may occur
CAUTION
mminor to medium personal injury or
menvironmental pollution or
mproperty damage - may occur

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2.2.1 Hazard information structure
The following two examples show you how the hazard informations are constructed. The
triangle is used when indicating a hazard forhuman beings. When there is a circle instead
of the triangle, the hazard information is only for possible property damage.
The text beneath the icons is constructed as follows:
2.2.2 Form of the hazard sign (triangular or round)
If there is a triangle like or or in front of the signal word, the hazard information
is referring to personal damage.
If there is a round hazard signal like in front of the signal word, the hazard information
is referring to property damage.
A triangle indicates hazard for human beings.
The shade of grey of the outline reflects the severity of the hazard - darker grey means rising
hazard.
The icon within the square illustrates the hazard.
The outline´s shade of grey reflects the severity of the hazard - darker grey means rising haz-
ard. (Not every hazard information has a square representing the hazard, so we have shown
it as draft here)
The icon in the circle represents a command.
(Not every hazard information has a circle representing the hazard, so we have shown it as
draft here)
The circle indicates hazard for property.
The icon within the square illustrates the hazard.
The outline´s shade of grey reflects the severity of the hazard - darker grey means rising haz-
ard. (Not every hazard information has a square representing the hazard, so we have shown
it as draft here)
HERE STANDS THE SIGNAL WORD WHICH INDICATES THE DEGREE OF THE HAZ-
ARD
Here we tell if one or more of the consequences described lower will occur if this hazard in-
formation is not observed.
mhere we describe the possible consequences. The worst consequence stands on the right
side.
Here we describe the hazard.
Here we describe what you can do to avoid this hazard.

Hazard information and commands
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2.2
2.2.2.1 Hazard information on personal injury
To distinguish each class of hazard information, we use a characteristic outline for both
the triangular hazard signs and the square-form icons
For the hazard class DANGER the danger sign is used. The hazard information of
this hazard class used in this documentation is listed below:
For the hazard class WARNING the warning sign is used. The following hazard infor-
mation of this hazard class is used in this documentation.
DANGER
The following will occur,if you do not observe this danger information:
mserious personal injury mdeath
The hazard is: electricity. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
The hazard is: electricity. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
The hazard is: electro-magnetic radiation. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.

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2
For the hazard class CAUTION the caution sign is used when there is hazard for per-
sons or of environmental pollution. The following hazard information of this hazard class
is used in this documentation.
CAUTION
The following may occur,if you do not observe this caution information:
mminor to medium personal injury.
The hazard is: hot surface. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.
CAUTION
The following may occur,if you do not observe this caution information:
mminor to medium personal injury.
The hazard is: sharp edges. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.
CAUTION
The following may occur,if you do not observe this caution information:
mminor to medium personal injury.
The hazard is: injury of the eye caused by ricocheting particles. Here the hazard may be
described in detail.
Here is described what you can do to avoid the hazard.
CAUTION
The following may occur,if you do not observe this danger information:
menvironmental pollution.
The hazard is: inadequate disposal. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.

Information sign
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2.3
2.2.2.2 Hazard information on property damage
If there is a round caution sign in front of the signal word, the safety information refers
to property damage.
2.2.2.3 Command signs used
2.3 Information sign
CAUTION
The following may occur,if you do not observe this caution information:
mproperty damage.
The hazard is: electro-static discharge. Here the hazard may be described in detail.
Here is described what you can do to avoid the hazard.
wear safety gloves
wear safety shoes
wear eye protection
wear ear protection
Use this fire extinguishing agent:
„fire extinguishing agent“
NOTE
This note is a very important information.

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2.4 Legal instructions
This documentation is addressed to technical qualified personnel, who is specifically
skilled and who is thoroughly familiar with all warnings and maintenance procedures.
The devices aremade according to the state-of-the-art technology andare fail-safe.They
can be installed safe, can be put into operation and they function without problems, if it is
assured, that the instructions of the documentation are followed.
The user is responsible for the execution of service and commissioning according to the
safety instructions of the prevailing standards and other relevant national and local in-
structions concerning conductor dimensioning and protection, earthing, disconnector,
overcurrent protection and so on.
For damages, which result from the mounting or from the connection, the one is liable,
who has carried out the mounting or the installation.
2.5 Appropriate use
Always use the device according to the terms. Stated below we have carried a few impor-
tant notes together. The notes stated below shall give you a feeling for the according to
the terms usage of the device. We do not raise any claim for the completion of the notes
stated below - follow all instructions given in this operating instruction.
mproject the application in such a way, that you always operate the device within its
specification.
muse this device only as converter for drives.
mmake sure, that only qualified personnel work with/at this device.
minstall this device only on an adequate carrying wall.
minstall this device in the way as it is described in the documentation.
mmake sure, that the mains/power supply unit always applies to the predetermined
specifications.
monly operate the device, if it is technical faultlessly.
moperate this device only in combination with released components of the company
Baumüller Nürnberg GmbH.
malways operate the device in an area as it is instructed in the „Technical data“.
malways operate the device in serialized condition.
Due to safety reasons you must not rebuild the device.
mconsider all instructions referring to this, if you intend to store the device.
You are using the device according to the terms, as soon as you regard all notes and in-
formation in this operating manual.

Inappropriate use
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2.6
2.6 Inappropriate use
Listed below you will find some examples of non-appropriate application. The information
below is intended to give you some impression of what non-appropriate application is.
However we cannot state all possible non-appropriate applications here. All applications,
where the notes and information given in this documentation is disregarded, are non-ap-
propriate and therefore forbidden.
Examples:
mYou disregarded the notes in this manual.
mThe device has not been specifically applied as a converter in order to control a motor.
nThe device has been
mmounted incorrectly,
mconnected incorrectly,
mcommissioned incorrectly,
moperated incorrectly,
mmounted, connected, commissioned, operated and/or maintained by not qualified or
inadequately qualified personnel,
minappropriately maintained or not maintained
(also consider the descriptions of the components),
moverloaded it,
noperated
mwith defective safety devices,
mwith incorrectly mounted safety devices or without safety devices,
mwith incorrectly working safety- and protection devices,
moutside the specified environmental conditions.
mYou have modified the device.
mYou have insufficiently monitored the parts, which are subject to a wearing.
mYou have improperly carried out a repair.
mYou have combined the device with improper products, which are not enabled for de-
vices described in this manual.
mYou have combined the device with faulty and/or faulty documentated products of oth-
er manufacturers.
mThe device has been operated in an explosive environment.
2.7 Safety equipment
The devices b maXX®BM1000 comply with the protection class IP 20.
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
The danger is: electricity.
Operate the device in a control cabinet, which provides a protection against a direct touching
of the devices and fulfills at least the demands of the EN61800-5-1, chapter 4.2.3.3.

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2.8 Training of the personnel
Qualified personnel (professionals) is defined below:
Qualified
personnel Authorized electronic engineers and skilled persons of the customer or third persons, who
have learned the installation and commissioning of Baumüller drive systems and who are
authorized, to put circuits and devices into operation according to the standards of the
safety technology, to ground and to label.
Qualified personnel has a training or an instruction due to the local valid standards of the
safety technique in maintenance and usage of an adequate safety equipment.
Requirements to
the operating per-
sonnel
The operating of the drive system must only be executed by persons, who have had a
training, who have been instructed and who have been authorized for this.
Fault clearance, servicing, cleaning, maintenance and exchange must only be carried out
by skilled or instructed personnel. These persons must know the operating manual and
must act according to this.
The commissioning as well as the instruction must only be carried out by qualified per-
sonnel.
2.9 Safety precautions in normal operation
hat the location of your appliance regard the safety regulations for the plant, into which
the appliance has been built in.
hif safety regulations require additional monitoring or safety devices supply your appli-
ance with them.
2.10 Dangers due to residual energy
Electrical
residual energy After separation of the device from the mains parts under voltage as e. g. power connec- tions may be only then touched if the capacitors in the device are discharged. To prevent
personal injury, please ensure that power has been turned off before opening the
bmaXX®BM1000 and wait ten minutes for the capacitors to discharge to safe voltage
levels.
Mechanical
residual energy The mechanical residual energy is dependent upon the application. As we don't know the
application, we cannot make any exact statements. Driven parts also rotate/move after
disconnection of the mains supply for a certain time. Please, provide adequate safety ar-
rangements.
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
Devices of the company Baumüller Nürnberg GmbH may only be assembled, installed,
operated and maintained by qualified personnel.

Disposal of the device
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2.11
2.11 Disposal of the device
The accurate disposal of the device is described in Z12 Disposal– on page 113.
2.12 Fire fighting
2.13 Responsibility and liability
To be able to work as safe as possible with this device, you must know and follow the
danger notes as well as the safety instructions.
2.13.1 Observing the safety notes and safety instructions
In this manual we use visually unified safety instructions, which are intended to prevent
from personal injury or damage to property.
2.13.2 Dangers when handling this device
The device „b maXX®“ was developed and manufactured according to the state-of-the-
art technology and in compliance with the valid regulations and standards. It is still pos-
sible that dangers can arise during use. An overview of possible dangers is to be found
in chapter ZFundamental safety instructions– from page 11.
We warn you against the acute danger at the respective places in this manual.
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
The danger is: Electricity when using a conductive fire fighting appliance.
Use this fire extinguishing agent:
ABC powder / CO2
WARNING
The following may occur,if you do not observe this warning information:
mserious personal injury mdeath
All persons, who work with this device, must know and regard the safety notes and the safety
instructions in this manual.
Apart from this, any and all persons who work on this device must additionally know and re-
gard to all regulations and instructions, that are valid at the location.