Baumuller b maXX BM3400 Series User manual

E5.07013.03
Instruction Manual
b maXX® BM3400

Titel Instruction Manual
Product b maXX® BM3400
Version 5.07013.03
Status December 1, 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 operating instructions
are not permitted.
Designation and company marks contained in these operating instructions
may be brand names, the use of which by third parties for their own pur-
poses may violate the rights of the holders.
Obliga-
tory
These operating instructions are part of the equipment / machine. 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 location 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 inval-
idated. Please notice that specifications / data / information are current
values according to the printing date. These statements are not legally
binding according to the measurement, computation and calculations.
Baumüller Kamenz GmbH reserves the right, in developing its products fur-
ther, to change the technical specifications and the handling of the products
concerned without prior notice.
No liability can be accepted concerning the correctness of the operating in-
structions unless otherwise specified in the General Conditions of Sale and
Delivery.
Manufac-
turer
Baumüller Kamenz GmbH
Nordstraße 57
01917 Kamenz
Deutschland
Tel. [phone] Fax: [phone]
www.baumueller- kamenz.de

Contents
1 Intro dution 11
1.1 Validity of this documentation ....................................... 11
1.2 Survey of the appliance series b maXX® BM3400 ............................ 12
1.3 First steps ................................................... 12
1.4 Used terms ................................................... 12
1.5 Copyright and trade marks ......................................... 12
2 Fundamental safety instrutions 13
2.1 General notes ................................................. 13
2.2 Hazard information and commandments ................................. 14
2.2.1 Structure of a hazard information ................................. 15
2.2.2 Shape of the hazard symbol (triangular or round) ........................ 16
2.2.2.1 Hazard information against personal injuries ..................... 16
2.2.2.2 Hazard information against damage to property ................... 19
2.2.3 Used mandatory signs ........................................ 19
2.3 Information sign ............................................... 20
2.4 Legal instructions ............................................... 21
2.5 Appropriate use ................................................ 21
2.6 Inappropriate use ............................................... 23
2.7 Protective devices ............................................... 24
2.8 Training of the personnel .......................................... 24
2.9 Safety precautions in normal operation .................................. 26
2.10 Dangers due to residual energy ....................................... 26
2.11 Safety categories ............................................... 26
2.12 Safe stop .................................................... 27
2.13 Disposal of the device ............................................ 29
2.14 Fire fighting .................................................. 29
2.15 Responsibility and liability ......................................... 30
2.15.1 Observing the safety notes and safety instructions ....................... 30
2.15.2 Dangers when handling this device ................................ 30
2.15.3 Warranty and liability ........................................ 30
3 Transp ortation and paking 31
3.1 To be considered by transportation .................................... 31
3.2 Unpacking ................................................... 32
3.3 Dispose packing ................................................ 32
4 Desription of the devie 33
4.1 Structure .................................................... 34
4.2 Connect together devices .......................................... 35
4.3 Overview of dangerous areas ........................................ 36
4.4 Marking of the device - type key ...................................... 37
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4.4.1 Type key version 1 .......................................... 37
4.4.2 Type key version 2 .......................................... 39
4.4.3 Type key version 3 .......................................... 41
5 Mounting 43
5.1 General safety instructions ......................................... 44
5.2 Requierements to the executing personnel ................................ 45
5.3 Prepare mounting ............................................... 46
5.4 Installation space ............................................... 47
5.5 Drill patterns .................................................. 49
5.6 Mounting instructions ............................................ 51
6 Installation 53
6.1 General safety instructions ......................................... 54
6.2 Requierements to the executing personnel ................................ 55
6.3 Voltage check ................................................. 56
6.4 Requirements to the electrical mains ................................... 56
6.5 Requirements to the connecting cables .................................. 57
6.6 Protection of the device and the cable respectively ........................... 57
6.7 Protective conductor and compatibility to RCD ............................. 60
6.8 Measures for EMC assurance ........................................ 61
6.8.1 Cabling ................................................. 61
6.8.2 Earthing ................................................ 64
6.8.3 Screening ............................................... 65
6.8.4 Mains filter ............................................... 67
6.9 Requirements to the temperature sensor of the motor ......................... 68
6.10 Operating sequence of installation ..................................... 69
6.11 Connection diagram ............................................. 70
6.12 Connection diagrams ............................................. 72
6.12.1 Devices according to type key V1 .................................. 73
6.12.1.1 HS0 single phase V1 (BM340X-L1XX-XXXX-O) ..................... 74
6.12.1.2 HS1 triple phase V1 (BM341X-L3XX-XXXX-O) ..................... 76
6.12.2 Devices according to type key V2/V3 ............................... 78
6.12.2.1 HS0 single phase V2/V3 (BM340X-L1XXX-XXXXXXX-O) ............... 79
6.12.2.2 HS0 triple phase V2/V3 (BM340X-L3XXX-XXXXXXX-O) ............... 81
6.12.2.3 HS1 single phase V2/V3 (BM341X-L1XXX-XXXXXXX-O) ............... 83
6.12.2.4 HS1 triple phase V2/V3 (BM341X-L3XXX-XXXXXXX-O) ............... 85
6.12.2.5 HS2 triple phase V2/V3 (BM342X-L4XXX-XXXXXXX-O) ............... 87
6.13 Terminals at the front of the controller board ............................... 91
6.13.1 Encoder interfaces .......................................... 92
6.13.1.1 Resolver (X24, Coding A) ................................. 92
6.13.1.2 Sine wave incremental encoder (X24, X25, Coding B) ................. 93
6.13.1.3 Hiperface absolute encoder (X24, X25, Coding C) ................... 94
6.13.1.4 Square wave incremental encoder (X24, X25, Coding E) ............... 95
6.13.1.5 Encoder connecting cables ................................ 96
6.13.2 Digital inputs and outputs ...................................... 97
6.13.3 Analog inputs and outputs ..................................... 99
6.13.4 Communication interface RS232 .................................. 101
6.13.5 Fieldbus interface CAN ....................................... 102
6.13.6 Incremental encoder emulation (optional extender board) .................. 103

6.13.6.1 Connecting cable for incremental encoder emulation ................ 103
6.13.7 EtherCAT-Slave (optional extender board) ............................ 104
6.14 Circuit of the chopper transistor ...................................... 106
6.15 Safety relay (option) ............................................. 107
6.16 Connection data for the terminals ..................................... 110
7 Op eration 111
7.1 Safety instructions .............................................. 111
7.2 Requierements to the executing personnel ................................ 112
7.3 Operating concept .............................................. 113
7.3.1 Enable signals ............................................. 113
7.4 Switch-on frequency ............................................. 114
7.5 Display elements - LED ........................................... 116
7.5.1 Current limit (H1) ........................................... 116
7.5.2 Operating condition (H2, H3) .................................... 116
7.5.3 Life sign (H4) ............................................. 116
7.6 Safety relay (option) ............................................. 117
7.7 Monitorings .................................................. 117
7.8 Error memory ................................................. 118
7.9 Maintenance .................................................. 118
8 Error detetion and trouble sho oting 119
8.1 Safety instructions .............................................. 119
8.2 Requierements to the executing personnel ................................ 119
8.3 Monitoring functions ............................................. 119
8.3.1 Monitoring functions - explanations ................................ 122
8.4 Error detection ................................................ 123
8.4.1 Structure of the error list - Survey of the error parameters ................... 126
8.5 Trouble shooting ............................................... 127
8.5.1 Reset errors .............................................. 127
8.5.2 Error parameters - error messages (error list) - error reactions ................ 128
8.5.3 Parameter description - Warnings (Warning bit list) ...................... 138
9 Maintenane 141
9.1 Safety instructions .............................................. 141
9.2 Environmental conditions .......................................... 141
9.3 Inspection intervals - maintenance notes ................................. 142
10 Repair 143
11 Setting out of op eration, storage 145
11.1 Safety instructions .............................................. 145
11.2 Requierements to the executing personnel ................................ 145
11.3 Setting out of operation ........................................... 146
11.4 Demounting .................................................. 147
11.5 Storage conditions .............................................. 148
11.6 Recommissioning ............................................... 148
12 Disp osal 149
12.1 Safety instructions .............................................. 149
12.2 Requierements to the executing personnel ................................ 150

12.3 Disposal instructions ............................................. 151
12.3.1 Modules ................................................ 151
12.4 Recycling plants / offices ........................................... 152
A App endix A - Abbreviations 153
B App endix B - Spare parts and aessories 155
B.1 Terminal accessories ............................................. 155
B.2 Memory module ............................................... 157
B.3 CAN cable termination resistor ....................................... 157
B.4 Screening plates ................................................ 157
B.5 Encoder connecting cables ......................................... 158
B.6 Motor cables .................................................. 159
B.7 EtherCAT- resp. Ethernet-cables ...................................... 159
C App endix C - Delaration of Conformity, Delaration by Manufaturer, UL-ertiation 161
C.1 What is an EU directive ........................................... 161
C.2 What the CE symbol indicates ....................................... 161
C.3 Definition of the term Declaration of Conformity ............................ 162
C.4 Definition of the term Declaration by Manufacturer .......................... 162
C.5 Declaration of Conformity .......................................... 164
C.6 Declaration by Manufacturer ........................................ 166
C.7 UL-Certification ................................................ 167
D App endix D - Tehnial data 169
D.1 Supported earthing systems ......................................... 170
D.2 Requirements to the power supply ..................................... 171
D.3 Requirements to the motor ......................................... 172
D.4 Required environmental conditions .................................... 172
D.5 Non-electrical data .............................................. 173
D.6 Electrical data - b maXX® BM3400 .................................... 174
D.6.1 Controller board ........................................... 174
D.6.1.1 Resolver interface ..................................... 174
D.6.1.2 Sine wave incremental encoder interface ........................ 175
D.6.1.3 Hiperface absolute encoder interface .......................... 175
D.6.1.4 Square wave incremental encoder interface ...................... 175
D.6.1.5 Digital inputs and outputs ................................ 176
D.6.1.6 Analog inputs and outputs ................................ 176
D.6.2 Incremental encoder emulation (option) ............................. 177
D.6.3 Safety relay (option) ......................................... 178
D.6.4 Power unit ............................................... 179
D.7 Overload durations .............................................. 185
D.8 Current derating depending on the output frequencies ......................... 186
D.9 Fuse protection ................................................ 187
D.9.1 Cable protection ........................................... 187
D.9.2 Device protection ........................................... 188
D.9.3 Cable protection and device protection .............................. 188
D.9.4 24V-extra-low voltage protection .................................. 188
D.10 Circuit mains - device ............................................ 189
D.11 Circuit device - motor ............................................ 189
D.12 Cable control voltage supply / signals ................................... 189

0.0T
D.13 Mains filter ................................................... 190
D.14 Line reactors .................................................. 190
D.15 Temperature sensors of the motor ..................................... 190
D.16 Fire fighting appliances ........................................... 190
E App endix E - List of gures 191
F App endix F - Index 195
G App endix G - Revision history 203
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10 Instrution Manual b maXX ® BM3400
from 206 Doument No.: 5.07013.03 Baumueller Kamenz GmbH