Baumuller b maXX 4100 Series User manual

Operation manual
Please read these operating instructions before beginning!
Language English
Translation
Document No. 5.04052.09
Part No. 392407
Status 21-Feb-2014
b maXX 4100
Active mains inverter (NWR)
E5.04052.09

Copyright These Operation manual may be copied by the owner in any quantity, but only for internal
use. This Operation manual may not be copied or reproduced, in whole or in part, for any
other purposes.
The use and disclosure of information contained in these Operation manual are not permit-
ted.
Designations and company marks contained in these Operation manual could be trade-
marks, the use of which by third parties for their own purposes could violate the rights of the
rights holder.
Advance information Warning Insofar as this document is identified as being advance 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 advance 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 advance informa-
tion, 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 advance information to the final infor-
mation (as reviewed by Baumüller).
The conditions stipulated in the following section under "Obligatory" are invalid in case of ad-
vance information.
Obligatory These Operation manual are a part of the equipment/machine. These Operation manual
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 Operation manual 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 Operation manual are handed over, corresponding sets of operating in-
structions 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 Operation manual unless
otherwise specified in the General Conditions of Sale and Delivery.
Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
90482 Nuremberg
Germany
Tel. [phone] - 0
Fax: [phone] - 1 30
Email : [email protected]
Internet: www.baumueller.de

Operation manual b maXX BM4100 (NWR)
Document no.: 5.04052.09
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Table of contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information on the instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 List of other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Contents of the instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Usage for the intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.11 Conduct in case of danger or accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.12 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.1 System types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.2 Requirements to the energy supply / supply system. . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.3 Required environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.4 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.1 Electrical data - BM4135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.2 Electrical data - BM4145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.3 Electrical data - BM4163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.4 Electrical data BM4-F-SEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.5 Electrical data BM4-F-SRM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Table of contents
4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Controller unit variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.1 Slots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2.1.1 Combination possibilities plug-in module-controller slots. . . . . . . . . . . . . . . . . . . . . 40
4.3 Connecting devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5 Type code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Marking of the function modules - type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.7 UL notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.8 Display and operation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.8.1 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.8.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Transport inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.5 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 Preparing for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2.1 Drilling patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.3 Demands on the power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.4 Requirements to the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.5 Protection of the device and the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.6 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.7 Installation requirements with regard to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.8 Mains filter and surge-protection module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.9 Main contactor and charge contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.10 HF mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.11 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.12 Connection diagram with SEA-01 / SRM-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.13 Proposal control power on/off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.14 Proposal main contactor control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.15 Proposal controlling pulse enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.16 Discharge DC-link / chopper resistor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.17 Proposal against system reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.18 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.18.1 Connector data of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.18.2 Requirements for the screwing (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Operating concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.2.1 Enable signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3 Power on switching frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.4 Notes for operation status „unregulated DC link voltage“ . . . . . . . . . . . . . . . . . . . . . . . 83
8.5 Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9 Troubleshooting and fault correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2 Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.2.1 Monitoring functions - explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.3 Fault detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.4 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4.1 Error reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.4.2 Error parameters, error messages, error reactions . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.4.2.1 Error messages (2nd level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.4.2.2 Sub-error messages (3rd level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9.4.3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.2 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.3 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.3.1 Periodic maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
11 Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
11.1 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
11.1.1 Cables power supply-device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
11.1.2 Cables device (DC link) - axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11.1.3 PE connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11.1.4 Cable mains - function module (UME, SRM and SEA) . . . . . . . . . . . . . . . . . . . . . . 114
11.1.5 Cable mains - charge circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
11.1.6 Cable control voltage supply/signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
11.1.7 Cable - signals X100-3 and X100-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
11.1.8 Interface cable RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
11.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
11.2.1 Pre-charge protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11.2.2 24V extra-low voltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11.3 Mains filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.4 Surge protection module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.4.1 Maintenance/inspection of surge protection modules . . . . . . . . . . . . . . . . . . . . . . . 120
11.5 Power chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
11.6 Main contactor and charge contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.7 Baumüller accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.7.1 Shielding clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.7.2 Cable RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.7.3 Design cover and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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Table of contents
12 Shutdown, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
12.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
12.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
12.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
12.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
12.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
12.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
13 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
13.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
13.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Appenidx A - Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Appenidx B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
B.1 Declaration of conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Table of figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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1GENERAL
1.1 Information on the instruction handbook
These instruction handbook provides important information on handling the device. A pre-
requisite for safe work is compliance with all specified safety notes and procedural in-
structions.
Additionally, the valid accident prevention regulations and general safety regulations ap-
plicable to the scope of application the device must be complied with.
Read the instruction handbook, particularly the safety notes chapter, completely before
beginning any work on the device. The instruction handbook is part of the product and
must be kept accessible to personnel at all times in the immediate vicinity of the device.

Key to symbols
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1.2
1.2 Key to symbols
Warning notes
Warning notes are identified by symbols in these instruction handbook. The notes are in-
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 or-
der to prevent accidents, personal injury and material damage.
Recommen-
dations
DANGER!
....points out an immediately dangerous situation that will lead to severe injuries or
death if not avoided.
WARNING!
....points out a potentially dangerous situation that could lead to severe injuries or
death if not avoided.
CAUTION!
....points out a potentially dangerous situation that could lead to minor or slight inju-
ries if not avoided.
NOTICE!
....points out a potentially dangerous situation that could lead to material damage if
not avoided.
NOTE!
....highlights useful tips and recommendations, as well as information for efficient and
problem-free use.

General
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1
1.3 Limitation of liability
All specifications and notes in these instruction handbook were compiled taking into ac-
count the applicable standards and regulations, the state of the art and our knowledge
and experience of many years.
The manufacturer assumes no liability for damages due to:
mnoncompliance with the instruction handbook
musage for other than the intended purpose
musage by untrained personnel
The actual scope of delivery can vary in case of optional equipment, laying claim to addi-
tional order options, or on account of the latest technical changes to the explanations and
representations described herein.
The user bears the responsibility for performing service and initial operation in accor-
dance with the safety regulations of the applicable standards and all other relevant gov-
ernmental or local regulations concerning the dimensioning and protection of conductors,
grounding, disconnectors, overcurrent protection, etc.
The person who carried out the mounting or installation is liable for any damage incurred
when assembling or connecting the device.
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.
1.5 Other applicable documents
Components of other manufacturers are integrated into the device. For these purchased
parts, hazard assessments have been performed by the respective manufacturers. The
compliance of the design construction with the applicable European and national regula-
tions has been declared for the components by the respective manufacturers.
1.6 Disposal
Insofar as no take-back or disposal agreement has been made, please disassemble units
correctly and properly recycle the constituent parts.
See also ZDisposal– on page 131.
NOTE!
The specific contents, text, drawings, images and other representations are copy-
righted and subject to industrial property rights. Any prohibited usage is punishable
by law.
b maXX®is a registered trademark of Baumüller Nürnberg GmbH

Spare parts
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1.7
1.7 Spare parts
Procure spare parts through an authorized dealer or directly from the manufacturer.
See also ZAccessories and Spare Parts– from page 111.
1.8 Guarantee provisions
The guarantee provisions are stated in a separate document of the sales documents.
The devices described herein may only be operated in accordance with the stipulated
methods, procedures and conditions. Anything else not presented here, including the op-
eration of devices in mounted positions, is not permitted and must be cleared with the
plant on a case-by-case basis. If the devices are operated in any other manner than as
described within these instruction handbook, then all guarantee and warranty rights are
rendered null and void.
1.9 Customer service
Our customer service is available to provide you with technical information.
Info on the responsible contact persons is available at all times via telephone, fax, mail or
the Internet.
1.10 Terms used
The term „device“ or the item designation BM4XXX are also used in this documentation
for this Baumüller product. A list of the abbreviations used can be found in ZAppendix A
- Abbreviations– from page 133.
1.11 List of other applicable documents
Parameter hand-
book
WARNING!
False or flawed spare parts can lead to damage, malfunction or complete fail-
ure, thus endangering safety.
Therefore:
mOnly use original spare parts of the manufacturer.
Doc No. Part No.
German
Part No.
English
Parameter manual basic unit b maXX b maXX 4100 mains inverter 5.04054 392423 392424

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2SAFETY
This section provides an overview of all of the important safety aspects for optimum pro-
tection 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.

Usage for the intended purpose
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2.3
2.3 Usage for the intended purpose
The device is conceived and constructed exclusively for usage compliant with its intended
purpose described in these instruction handbook.
The devices of the model series BM4100 (NWR) is used exclusively as an active mains
rectifier.
A device is considered as being used compliant with its intended purpose if all notes and
information of these instruction handbook are adhered to.
WARNING!
Danger arising from usage for an unintended purpose!
Any usage that goes beyond the intended purpose and/or any non-compliant use of
the device can lead to dangerous situations.
Therefore:
mOnly use the device compliant with its intended purpose.
mObserve all specifications of these instruction handbook.
mEnsure that only qualified personnel work with/on this device.
mWhen configuring, ensure that the device is always operated within its specifica-
tions.
mMount the device on a wall that can sufficiently bear the load.
mThe device must always be operated within a control cabinet.
mEnsure that the power supply complies with the stipulated specifications.
mThe device may only be operated in a technically flawless condition.
mOnly operate the device in combination with components approved by Baumüller
Nürnberg GmbH.
mThe device has been developed in such a manner that it fulfills the requirements
of the category C3 according to IEC 61800-3:2005.
mThe device is not intended to be connected to the public power supply system. To
operate the device in primary surroundings of the category C2/C1 (residential,
business and commercial areas, directly on a public low-voltage power supply
without an intermediate 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.

Safety
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2
2.4 Responsibility of the operating company
The device will be used in commercial areas. Thus, the proprietor of the device is subject
to the legal work safety regulations.
Along with the notes on work safety in these instruction handbook, the safety, accident
prevention and environmental protection regulations valid for the area of application of
this device must be complied with. Whereby:
mThe operating company must inform himself about the applicable work health and safe-
ty regulations and ascertain, in a hazard assessment, any additional hazards that could
arise from the special working conditions in the use area of the device. These must
then be implemented in the form of instruction handbook for operation of the device.
mThese instruction handbook must be kept accessible to personnel working with the de-
vice at all times in the immediate vicinity of the device.
mThe specifications of the instruction handbook must be adhered to completely and
without exception.
mThe device may only be operated in a technically faultless and operationally safe con-
dition.
2.5 Protective devices
The devices BM4135 and BM4145 meet the international protection IP10. BM4163 meets
the international protection IP00. All mentioned devices have to be installed into a suitable
control cabinet to meet the international protections required by the EN 61800-5-1, chap-
ter 4.2.3.3. (IP30: only upper, horizontally surfaces; IP20: all other surfaces).
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted.
Therefore:
mThe device must be in operated inside of a control cabinet that provides protection
against direct contact of the devices and at least meets the requirements of
EN 61800-5-1, Chapter 4.2.3.3.

Training of the personnel
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2.6
2.6 Training of the personnel
In these instruction handbook, the following qualifications are stipulated for various areas
of activity:
mOperating personnel
nThe drive system may only be operated by persons who have been specially trained,
familiarized and authorized.
nTroubleshooting, 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.
nInitial operation and familiarization may only be performed by qualified personnel.
mQualified personnel
nElectrical engineers authorized by Baumüller Nürnberg GmbH, and qualified electri-
cians of the customer or a third party who have learned to install and maintain
Baumüller drive systems and are authorized to ground and identify electrical power
circuits and devices in accordance with the safety engineering standards of the com-
pany.
nQualified 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.
WARNING!
Risk of injury due to insufficient qualifications!
Improper handling can lead to significant personal injury and material damage.
Therefore:
mCertain activities can only be performed by the persons stated in the respective
chapters of these instruction handbook.

Safety
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2.7 Personal protective equipment
The wearing of personal protective equipment is required when working in order to mini-
mize health and safety risks.
mThe protective equipment necessary for each respective type of work shall always be
worn during work.
mThe personal safety signs present in each working area must be observed.
Wear for special
work.
Protective work clothing
should be snug-fitting work clothes, with low tearing resistance, narrow sleeves and
with no extending parts. It serves to primarily protect against...
No rings or chains should be worn.
Hard hat
to protect against falling down and flying around objects.
Safety shoes
to protect against heavy objects falling down.
Protective gloves
to protect hands against friction, abrasion, puncturing or more severe injuries, as well
as contact with hot objects.
Protective eye wear
to protect the eyes against flying around objects and sprayed liquids.

Special hazards
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2.8
2.8 Special hazards
In the following section, the remaining marginal risks will be stated that have been iden-
tified as a result of the hazard analysis.
Observe the safety notes listed here and the warning notes in the further chapters of this
Operation manual to reduce health risks and dangerous situations.
Electrical current
Danger from re-
sidual energy
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted. Damage
to the insulation or individual components can be life-threatening.
Therefore:
mSwitch off the electrical power immediately in case of damage to the power supply
insulation.
mOnly allow work on the electrical system to be performed by qualified personnel.
mSwitch off the current when any kind of work is being performed on the electrical
system and ensure safety before switching on again.
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the rack system = discharge time of the device with the longest DC
link discharge time in the rack system.
See ZElectrical data– ab Seite 30.
Therefore:
mDo not touch electrically live parts before taking into account the discharge time of
the capacitors.
mPay attention to the corresponding notes on the device.
mIf additional capacitors are connected to the DC link, the DC link discharge can
take a much longer time. In this case, the necessary waiting period must itself be
determined or a measurement made as to whether the equipment is de-energized.
This discharge time must be posted, together with an IEC 60417-5036 (2002-10)
warning symbol, on a clearly visible location of the control cabinet.

Safety
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Moving compo-
nents
2.9 Fire fighting
WARNING!
Risk of injury from moving components!
Rotating components and/or components moving linearly can result in severe injury.
Therefore:
mDo not touch moving components during operation.
mDo not open any covering during operation.
mThe amount of residual mechanical energy depends on the application. Powered
components still turn/move for a certain length of time even after the power supply
has been switched off. Ensure that adequate safety measures are taken.
DANGER!
Risk of fatal injury from electrical current!
There is a risk of electric shock if an electrically-conductive, fire-extinguishing agent
is used.
Therefore:
mUse the following fire-extinguishing agent:
ABC powder / CO2

Safety equipment
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2.10
2.10 Safety equipment
2.11 Conduct in case of danger or accidents
Preventive mea-
sures
mAlways be prepared for accidents or fire!
mKeep first-aid equipment (e.g. first-aid kits, blankets, etc.) and fire extinguishers readily
accessible.
mFamiliarize personnel with accident alarm, first aid and rescue equipment.
And if something
does happen: re-
spond properly.
mStop operation of the device immediately with an EMERGENCY Stop.
mInitiate first aid measures.
mEvacuate persons from the danger zone.
mNotify the responsible persons at the scene of operations.
mAlarm medical personnel and/or the fire department.
mKeep access routes clear for rescue vehicles.
WARNING!
Risk of fatal injury due to non-functional safety equipment!
Safety equipment provides for the highest level of safety in a facility. Even if safety
equipment makes work processes more awkward, under no circumstances may they
be circumvented. Safety can only be ensured by intact safety equipment.
Therefore:
mBefore starting to work, check whether the safety equipment in good working order
and properly installed.

Safety
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2
2.12 Signs and labels
The following symbols and information signs are located in the working area. They refer
to the immediate vicinity in which they are affixed.
WARNING!
Risk of injury due to illegible symbols!
Over the course of time, stickers and symbols on the device can become dirty or oth-
erwise unrecognizable.
Therefore:
mMaintain all safety, warning and operating labels on the device in easily readable
condition.
Electrical voltage
Only qualified personnel may work in work areas that identified with this.
Unauthorized persons may not touch working materials marked correspondingly.
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the rack system = discharge time of the device with the longest DC
link discharge time in the rack system.
See ZElectrical data– ab Seite 30.
Therefore:
mDo not touch before taking into account the discharge time of the capacitors and
electrically live parts.
mHeed corresponding notes on the equipment.
mIf additional capacitors are connected to the DC link, the DC link discharge can
take a much longer time. In this case, the necessary waiting period must itself be
determined or a measurement made as to whether the equipment is de-energized.
This discharge time must be posted, together with an IEC 60417-5036 (2002-10)
warning symbol, on a clearly visible location of the control cabinet.

Signs and labels
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2.12
Figure 1: Signs and labels BM413X/BM414X
CAUTION!
Risk of injury due to hot surface!
Therefore:
mWear protective gloves
NOTE!
When in operation, the top of the device can heat up to temperatures > 70 °C!