Baumuller BUM 62 T User manual

E5.99009.03
Manual
BUM 62 T
Mono Power Unit

Title Manual
Product Mono Power Unit BUM 62 T
Version 5.99009.03
Status 2005-02-03
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 oper-
ating instructions may be brand names, the use of which by
third parties for their own purposes may violate the rights of
the holders.
Obligatory These operating instructions are part of the 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 location
these operating instructions must be passed on by the own-
er 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 de-
stroyed.
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 accord-
ing to the printing date. These statements are not legally
binding according to the measurement, computation and
calculations.
Baumüller Nürnberg GmbH reserves the right, in developing
its products further, to change the technical specifications
and the handling of the products concerned without prior no-
tice.
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

Mono Power Unit BUM 62 T 3
Baumüller Nürnberg GmbH 5.99009.03
TABLE OF CONTENTS
Table of contents
1 Safety notes ........................................................................................................ 7
2 Introduction ....................................................................................................... 11
3 Technical data ................................................................................................... 13
3.1 Table of technical data ......................................................................................................... 13
3.2 Type key ............................................................................................................................... 15
3.3 Block diagram ....................................................................................................................... 16
4 Transportation, Unpacking .............................................................................. 17
5 Assembly ........................................................................................................... 19
5.1 Free space ............................................................................................................................ 19
5.2 Installation information .......................................................................................................... 20
6 Installation ......................................................................................................... 23
6.1 Danger information ............................................................................................................... 23
6.2 EMC information ................................................................................................................... 25
6.3 Applicable standards ............................................................................................................ 31
6.4 Safety relay ........................................................................................................................... 33
6.4.1 Methods to avoid an unexpected starting .................................................................................... 33
6.4.2 Safety categories ......................................................................................................................... 34
6.4.3 The safety relay ........................................................................................................................... 34
6.4.4 Service time ................................................................................................................................. 38
6.5 Connection diagram ............................................................................................................. 39
6.6 Terminal strips and plug-in terminals .................................................................................... 40
6.6.1 Power connections ...................................................................................................................... 40
6.6.2 Control connections ..................................................................................................................... 42
6.6.3 Controller connection ................................................................................................................... 46
6.6.4 Safety relay (as an option) ........................................................................................................... 46
6.7 Accessories .......................................................................................................................... 47
7 Commissioning ................................................................................................. 49
7.1 Danger information ............................................................................................................... 49
7.2 Operation .............................................................................................................................. 52
7.3 Monitoring functions and their messages ............................................................................. 52
7.3.1 Ready for operation ..................................................................................................................... 53
7.3.2 Monitoring functions ..................................................................................................................... 55
7.3.3 Messages via LEDs ..................................................................................................................... 60
7.3.4 Messages via relay contacts ........................................................................................................ 61
8 Maintenance ...................................................................................................... 63
8.1 Maintenance information ...................................................................................................... 63
8.2 Environmental conditions ..................................................................................................... 64
8.3 Recommissioning ................................................................................................................. 64
8.4 Disposal ................................................................................................................................ 65

Table of contents
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5.99009.03 Baumüller Nürnberg GmbH
9 Appendix ........................................................................................................... 67
9.1 Manufacturer Declaration ..................................................................................................... 67
9.2 Declaration of Conformity ..................................................................................................... 68
9.3 General Conditions of Sale and Delivery .............................................................................. 69
9.4 Index ..................................................................................................................................... 72

Abbreviations
Mono Power Unit BUM 62 T 5
Baumüller Nürnberg GmbH 5.99009.03
ABBREVIATIONS
AC Alternating current
AM Asynchronous motor
BUM Baumüller
Mono Power Unit
BUS Baumüller
Power Module
DC Direct current
DIN Deutsches Institut für Normung e.V.
(German Standardization Authority)
EMC Electromagnetic compatibility
EN European Standard
MC Main contactor
IPM Intelligent power module
a.m.s.l. above mean sea level
PELV Protective extra-low voltage
SELV Safe extra-low voltage
PE Protective earth
SM Synchronous motor
ZK DC link

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Safety notes
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Baumüller Nürnberg GmbH 5.99009.03
1 SAFETY NOTES
Introductory remarks
During operation, the principles on which the converter and motor work, lead to leakage currents to earth
which are dissipated by use of the specified protective earth connections which may result in a current-
operated e.l.c.b. on the input side blowing prematurely.
A DC component in the fault current may occur in the event of a short-circuit to frame or earth fault which
could make triggering of the higher-level current-operated e.l.c.b. more difficult or even impossible.
Connection of the current controller to the mains using only the current-operated e.l.c.b. is prohibited
(preliminary standard EN 50178 / VDE 0160 /11.94, sections 5.2.11 and 5.3.2.1).
The units are protected against direct contact by being installed into common switching cabinets which
meet the minimum protection requirements according to EN 50178 / VDE 0160 / 11.94, section 5.2.4.
Sheets of plastic covering the control electronics, the power stage and the device connection,
additionally prevent accidental contact during commissioning and casual use of control elements located
close to the equipment.
(DIN VDE 0106 Part 100, Accident Prevention Regulation VBG4 ”Electrical Systems and Equipment).
The protective measures and safety regulations according to DIN/VDE are binding for personal security.
Neglecting to fit PE connections on the equipment or the motor will result in serious personal injury and/
or considerable damage of property.
General information
These operating instructions contain the information required for the application as directed of the
products described herein. The document is intended for specially trained, skilled personnel who are
well-versed in all warnings and maintenance activities. The units are manufactured using the state-of-
the-art technology and are safe in operation. They can be installed safely, commissioned and function
without problems if the safety information below is observed.
DANGER
When operating this electrical unit, some parts of the equipment always carry dangerous voltage.
Ignoring these safety instructions and warnings may result in death, serious personal injury and/or
damage of property.
Only qualified personnel who are familiar with the safety information, mounting, operation and
maintenance instructions may carry out work on this unit.

Safety notes
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5.99009.03 Baumüller Nürnberg GmbH
Danger information
In the context of the operating instructions and the information on the products themselves, the terms
used have the following meanings:
Qualified personnel
Qualified personnel in the sense of the safety-relevant information in this document or on the products
themselves, qualified personnel are considered to be persons who are familiar with setting up, mounting,
commissioning and operating the product and who have qualifications appropriate to their activities.
yTrained or instructed or authorised to commission, ground and mark circuits and equipment in
accordance with recognized safety standards.
yTrained or instructed in accordance with recognized safety standards in the care and use of
appropriate safety equipment.
One the one hand, the information below is for your own personal safety and on the other to prevent
damage to the described products or units connected to it.
DANGER
This means that death, severe personal injury or considerable property damage will occur,
unless appropriate safety measures are taken.
WARNING
This means that death, severe personal injury or considerable property damage may occur,
unless appropriate safety measures are taken.
NOTE
This draws your attention to important information about the product, handling of the product or to
a particular section of the documentation.

Safety notes
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Baumüller Nürnberg GmbH 5.99009.03
Application as directed
Voltage test
BAUMÜLLER carries out a voltage test according to EN 50178 / VDE 0160 /11.94, Section 9.4.5 for
each unit.
Subsequent high-voltage tests must only be carried out by BAUMÜLLER NÜRNBERG GmbH.
WARNING
You may only use the unit/system for the purposes specified in the operating instructions and in
conjunction with the third-party equipment and components recommended or authorised by
BAUMÜLLER NÜRNBERG GmbH.
For safety reasons, you must not change or add components on/to the unit. The operator must report
immediately any changes that occur which adversely affect the safety of the unit/system.
WARNING
If you want to carry out high-voltage tests for complete switch cabinet installations, disconnect all
cables from BAUMÜLLER units prior to the test.

Safety notes
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Introduction
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2 INTRODUCTION
The power units designated BUM 62 T are used for the upper power range.
Supply part (converter)
The supply part (mains side) for the generation of the DC link voltage is an uncontrolled diode bridge.
To reduce the peak making current (deburdening during switch-on), the DC link capacitors are charged
via a charge resistor which is bridged by a thyristor after switching-on.
If the typical motor power of the converter on the motor side (see electrical data) is not fully used, e.g.,
because the power of the connected motor is smaller, the performance of the supply current controller
can be used for the connection of other power modules of the BUS 6 series.
The total of all motor powers occurring at the same time must not be higher than the typical motor power.
Starting current load relief
If precautions are not taken, the DC link capacitors produce inadmissibly-large charging current surges
from the mains. In order to avoid these surges, the starting current is limited by a load relief device.
To this purpose, a resistance is integrated into the charging circuit. The resistance limits the charging
current (with the exception of temporary mains failure) and is bypassed once the DC link is charged.
The cycle time for connect the unit in circuit again is ≥3 min.
If using an additional external capacitor at the DC (external capacity ≥ 500 µF) the cycle time is
increased

Introduction
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Brake switch
The energy which is generated in the generator mode, is dissipated by the brake switch (brake chopper)
and an external regenerative resistor.
Inverter
The inverter on the motor side consists of the IGBT power part and the corresponding sensors. The
sensors supply measuring signals for the closed-loop control and also ensure the self-protection of the
power electronics.
The inverter is triggered by the controller used.
Baumüller rack modules are provided for the control. The drives can therefore be adapted to different
applications.
Controller
The BUM 62 T only operates in conjunction with an additional controller. The controller types are
equipped with modules. A separate description is available for the operation of the controllers.

Technical data
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Baumüller Nürnberg GmbH 5.99009.03
3 TECHNICAL DATA
3.1 Table of technical data
BUM 62 T - 100 / 130 - ...
Connection voltage (mains) 1) 3 x 400 VAC ±15% 50 Hz
3 x 460 VAC +10% -25% 60 Hz
Supply voltage 2) + 24 VDC -10% / +20 % (72W)
Continuous input power max. 50 kVA
Rated DC link voltage 3) 540 VDC
DC link capacity (internal) 1700 µF
DC link capacity (external) max. 500 µF
Cycle time for connect the unit in circuit again
(without additional DC link capacitors)
≥3 min
Output voltage 4) 3 x 0 VAC ... 3 x (conn. volt. -30 V)
Output frequency 5) 0 Hz. ...300 Hz
Continuous output power at 4 kHz 10) max.
62 kVA
Continuous output power at 8 kHz 10) max. 50 kVA
Continuous motor power at 4 kHz 10) max. 43 kW
Continuous motor power at 8 kHz 10) max.
35 kW
Rated output current 6) 7) 8) at 4 kHz 10) 100 A
Rated output current 6) 7) 8) at 8 kHz 10) 75 A
Peak output current 6) 7) 9) at 4 kHz 10) 130 A
Peak output current 6) 7) 9) at 8 kHz 10) 97 A
Connection power DC link connection 36 kW
External chopper current max. 73 A
Internal chopper resistor -
External chopper resistor ≥11 Ω
Application threshold of regenerative resistor 750 V
Ambient temperature range (operation) 11) min. 0 °C .... max. 55 °C
40 °C (nominal temperature)
Power loss 3) Connect. (mains)
Supply
1400 W
max. 72 W
Type of protection IP 20
Installation height 12)
max. 1000 m a.m.s.l.
relative humidity 15 % ... 85 % no condensation.
Temperature range for transport - 30 °C ... + 70 °C
Temperature range for storage - 30 °C ... + 70 °C
Dimensions (W x H x D) 264 x 560 x 280 mm
Weight without controller 30 kg

Technical data
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1. Voltage difference between phases must no exceed +/- 1.0 %.
2. According to EN 61131-2 (Table 5).
With a supply voltage < 24 V the fan power is reduced. Therefore, it may be necessary to reduce the
output current additionally.
3. All ratings refer to a connection voltage of 400 V and a supply voltage of 24 V.
4. The output voltage is a pulse-commutated DC. The setting range refers to the r.m.s. value of the
fundamental wave.
5. The output frequency depends on the controller used.
6. R.m.s. value at an ambient temperature of 40 °C.
7. The unit provides the rated/maximum output current up to the connection voltage. When the input
voltage exceeds the rated voltage, reduce the output currents at constant output power
proportionally.
Characteristic 1: Output currents in relation to the connection voltage.
8. The rated output current must be reduced between 40 °C and 55 °C. The rated output current is
calculated according to the following formula:
Example: Rated output current = 100 A, ambient temperature = 46 °C.
The rated output current must therefore be reduced to: 82 A
9. Maximum duration of the peak output current is 120 s. The duration depends on the motor current
and the temperature of the heat sink. See Technical Description/Operating Instructions of the
controller (V-controller: P139).
10. Chopping frequency of the inverter.
(see description parameter P103 in the description of the V-controller)

Technical data
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Baumüller Nürnberg GmbH 5.99009.03
11. The ambient temperature is determined as follows:
12. Characteristic 2: Values in relation to the installation height at normal air pressure.
3.2 Type key
yDetermine several measuring points
covering the entire area as illustrated at
a distance of 10 cm.
yMeasure the temperature at these
measuring points.
The highest value is
the ambient temperature.

Technical data
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3.3 Block diagram

Transportation, Unpacking
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4 TRANSPORTATION, UNPACKING
The units are packed at the factory in accordance with the order.
Avoid strong shaking during transportation and shocks, e.g. when setting the units down.
After unpacking the units and checking that the shipment is complete and undamaged, you can start
assembly.
The packing consists of fibreboard, corrugated cardboard and/or wood. It can be disposed according to
the local regulations.
Report any transport damage without delay.
DANGER
If you detect a transport damage on the unit, it must not be connected unless an appropriate voltage
test has been carried out.
Ignoring this information can result in death, severe personal injury or considerable damage to
material assets.

Transportation, Unpacking
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Assembly
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5 ASSEMBLY
5.1 Free space
*The total depth depends on the controller dimensions!
WARNING
The user is responsible for the assembly of the unit described, the motor, and the other devices
according to the safety regulations (e.g. EN, DIN, VDE) and all other relevant nations or local
regulations concerning the conductor ratings and protection, grounding, disconnectors, overcurrent
protection, etc.
The following measures for ventilation must be strictly observed.
Otherwise, the unit may be overheated.
yEnsure sufficient cooling air and ventilation!
yVentilation must be from the bottom to the top, ensure a free space above and below the unit (see
”Free space” on page 19).
yThe rated power of the unit is possible only up to a specific ambient temperature! The power must
be reduced when higher temperatures occur (see ”Table of technical data” on page 13).
yDo not locate any other sources of heat above the unit.
yPollution degree 3 and 4 according to EN 50178:1994 Section 5.2.15.2 must be avoided. The units
are suitable for the installation in closed operating rooms. (VDE 0558 Part 1a, Section 5.4.3.2.1 and
5.4.3.2.2)

Assembly
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5.2 Installation information
WARNING
Inappropriate lifting can cause personal injury or damage to material assets.
Qualified personnel only may lift the unit using suitable equipment.
yObserve the weight of the unit!
yuse protective gloves!
NOTE
yAlways mount the unit vertically at the back panel of the switch cabinet.
yArrange several units side by side