Baumuller BUG 3 Parts list manual

RGB ELEKTRONIKA AGACIAK CIACIEK
SPÓŁKA JAWNA
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Poland
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www.rgbelektronika.pl
OTHER SYMBOLS:
BUG2-60-31-B-010
BAUMÜLLER

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BAUMÜLLER
Technicaldescriptionand
operationmanual
Edition15.February 2002
BASIC
FEEDUNIT
BUG3/2/20
E
5.96064.02

BAUMÜLLER
BASIC FEED UNIT
BUG 3 / 2 / 20
Technical description and operation manual
Edition March 1997
5.96064.01
PLEASE READ AND PAY ATTENTION TO SAFETY INSTRUCTIONS
AND OPERATING GUIDE PRIOR TO COMMISSIONING
This manual contains the necessary information for normal opteration of the products described
therein. The drives may only be used, maintained and repaired by personnel familiar with the operation
manual and the applicable regulations on working safety and accident prevention. The devices are
manufactured to a high technical specification and are operationally safe. Provided that all safety
instructions habe been adhered to, there will be no personal danger during the installation and
commissioning stages.
The commisioning is prohibited until it has been positively determined that the machine, into which
these components are to be incorporated, complies with EC machine regulations.
This technical description replaces and nullifies all provious description. In order to provide the best
possible service, we reserve the right to alter information without notice.
Manufacturer and Baumüller Nürnberg GmbH
Supplier's address: Ostendstr. 80
90482 Nürnberg
Germany
Tel. (++49-911) 5432 - 0 Fax (++49-911) 5432 - 130
Copyright: The technical description and the operation manual may not be copied or
duplicated without our permission.
Country of origin: Made in Germany
Date of manufacture: Determined from the serial number on the machine/motor.

Table of Contents
BUG 3/2/20 Basic Feed Unit I
Baumüller Nürnberg GmbH 5.96064.02
TABLE OF CONTENTS
1 Safety Information..............................................................................................1
2 Technical Data....................................................................................................5
2.1 General............................................................................................................................5
2.1.1 Description of Function....................................................................................6
2.1.2 Block Diagram .................................................................................................7
2.2 Electrical Data .................................................................................................................8
2.3 Type Code .......................................................................................................................10
3 Transportation, Unpacking ...............................................................................11
4 Assembly ............................................................................................................13
4.1 Dimensions......................................................................................................................14
4.2 Assembly Information ......................................................................................................16
5 Installation ..........................................................................................................17
5.1 Danger Information..........................................................................................................17
5.2 EMC Information..............................................................................................................18
5.3 Connection Diagram........................................................................................................24
5.3.1 BUG 2 ..............................................................................................................25
5.3.2 BUG 3 ..............................................................................................................24
5.3.3 BUG 20 ............................................................................................................26
5.3.4 Connection Information....................................................................................27
5.4 Pin Assignments..............................................................................................................28
5.4.1 Power Terminals..............................................................................................28
5.4.2 Control Terminals ............................................................................................28
5.5 Accessories .....................................................................................................................29
5.5.1 Transformers ...................................................................................................29
5.5.2 Starting Current Limitation Device...................................................................32
5.5.3 BUR Resistor Unit............................................................................................34
5.5.4 BUK Capacitor Unit..........................................................................................37

Table of Contents
II BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH
6 Commissioning.................................................................................................. 41
6.1 Function Plan...................................................................................................................44
6.2 Messages and Warnings .................................................................................................46
6.3 Test Connector ................................................................................................................48
7 Maintenance....................................................................................................... 49
7.1 Maintenance Information .................................................................................................49
7.2 Disposal ...........................................................................................................................50
8 Appendix ............................................................................................................ 51
8.1 Manufacturer Declaration ................................................................................................51
8.2 Declaration of Conformity ................................................................................................52
8.3 Conditions of Business and Delivery...............................................................................53
8.4 Index ................................................................................................................................54

Abbreviations
BUG 3/2/20 Basic Feed Unit III
Baumüller Nürnberg GmbH 5.96064.02
ABBREVIATIONS
AC Alternating current
AM Asynchronous motor
BEDAS German abbreviation of Operating data store
BUC Baumotronic Converter Feed/Feed back Unit
BUG Baumotronic Converter Basic Feed Unit
BUM Baumotronic Converter Mono Power Unit
BUS Baumotronic Converter Servo Power Unit
DC Direct current
DIN German Standardization Institute
(Deutsches Institut für Normung e.V.)
EMC Electromagnetic compatibility
EN European standard
HS Main contactor
IPM Intelligent Power Module
MSL Mean sea level
PE Protective earth
SM Synchronous motor
ZK Intermediate circuit

Abbreviations
IV BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH

Safety Information
BUG 3/2/20 Basic Feed Unit 1
Baumüller Nürnberg GmbH 5.96064.02
1 SAFETY INFORMATION
Preliminary Remarks
During operation, the principles on which the power converter and the motor work lead to leakage
currents to earth that may be dissipated via the specified protective earths and may result in a current-
operated e.l.c.b. on the input side blowing prematurely.
In the case of a short-circuit to frame or to ground, a direct proportion may arise in the leakage current
that makes triggering a higher-level current-operated e.l.c.b. either more difficult or totally impossible.
This means that connecting the power converter 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 from direct contact by being installed in commercially available switching cabi-
nets that meet the minimum protection requirements of preliminary standard EN 50178/VDE
0160/11.94, Section 5.2.4.
Sheets of plastic covering the equipment connection act as additional guards preventing accidental
contact at commissioning and in the case of casual use of control elements located close to the
equipment (DIN VDE 0106 Part 100, Accident Prevention Regulation VBG4 "Electrical Systems and
Equipment").
At routine testing of this equipment, a high-voltage test is carried out that conforms with preliminary
standard EN 50178/VDE 0160/11.94, Section. 9.4.5.
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 to property.
The equipment may only be run on grounded supply networks.
Sections carrying current take more than one minute to discharge.
The equipment is conditionally shortcircuit-proof.
General Information
These operating instructions contain all the information necessary for correct operation of the products
described. The document is intended for specially trained, technically qualified personnel who are
well-versed in all warnings and commissioning activities.
The equipment/system is manufactured using state-of-the-art technology and is safe in operation. It
can safely be installed and commissioned and functions without problems if the safety information
below is followed.

Safety Information
2Basic Feed Unit BUG 3/2/20
5.96064.02 Baumüller Nürnberg GmbH
WARNING
When operating electrical equipment, some parts of the equipment always carry dangerous voltages.
Ignoring these safety instructions and warnings may result in serious personal injury and/or damage to
property.
Only qualified personnel who are familiar with the safety information, assembly, operation and mainte-
nance instructions may carry out work on this equipment.
Danger Information
On the one hand, the information below is for your own personal safety and on the other to prevent
damage to the described products or to other connected equipment.
In the context of the operating instructions and the information on the products themselves, the terms
used have the following meanings:
DANGER
This means that death, severe personal injury, or damage to property will occur unless appropriate
safety measures are taken.
WARNING
This means that death, severe personal injury, or considerable damage to property 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 Information
BUG 3/2/20 Basic Feed Unit 3
Baumüller Nürnberg GmbH 5.96064.02
Qualified Personnel
In the context of the safety-specific information in this document or on the products themselves, quali-
fied personnel are considered to be persons who are familiar with setting up, assembling, commis-
sioning and operating the product and who have qualifications appropriate to their activities.
Trained or instructed or authorized to commission, ground and mark circuits and equipment in accor-
dance with recognized safety standards.
Trained or instructed in accordance with recognized safety standards in the care and use of appropri-
ate safety equipment.
Appropriate Use
WARNING
You may only use the equipment/system for the purposes specified in the operating instructions and in
conjunction with the third-party equipment and components recommended or authorized by
BAUMÜLLER NÜRNBERG GmbH.
For safety reasons, you must not change or add components on/to the equipment/system.
The machine minder must report immediately any changes that occur which adversely affect the
safety of the equipment/system.
Appropriate use also includes observing the operating instructions and complying with the conditions
of inspection and maintenance.

Safety Information
4BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH

General Technical Data
BUG 3/2/20 Basic Feed Unit 5
Baumüller Nürnberg GmbH 5.96064.02
2 TECHNICAL DATA
2.1 General
The motor and the converter must be matched to one another to be able to fulfil the requirements
made of the drive system three-phase current servo motor and the converter. Our BAUMOTRONIC
converters, which have been specially developed for servo drives, are transistor converters for four-
quadrant operation.
The BAUMOTRONIC converter system is of modular structure and comprises the following units:
−the BUG basic feed unit
−the BUS servo power unit
The BUG 2/3/20 named basis feed units are mains-side power converters for feeding the BUS 3/21/20
drive amplifiers. They have a ballast circuit to dissipate the drive´s breaking energy. They are available
with internal ballast resistor or, as E version with a connector for external resistors.
Features:
−BUG 3 basic unit for up to 10.5 kW
−BUG 2 basic unit for up to 18 kW
−BUG 20 basic unit for up to 36 kW
−Connection using a pre-transformer of 400 V/230 V 3 ∼
−Servo power units' current supplied from the intermediate circuit
−Switching power supply with wide voltage range continues to be ready-for-use while the inter-
mediate circuit is charged
−Ballast circuit with high peak power integrated in the basic feed unit

Technical Data General
6BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH
2.1.1 Description of Function
Intermediate Circuit
The intermediate circuit, which supplies the connected servo units, is fed from the mains via an exter-
nal matching transformer and the uncontrolled bridge rectifier.
Starting Current Limitation Device
If no measures were taken, the intermediate circuit capacitors would lead to inadmissibly high charg-
ing current surges when you switch on the mains current. Mains transformers of up to 5 kVA automati-
cally reduce the charging current surge to a non-dangerous level. In the case of large transformers,
you must install a starting current limitation device on the input side.
This device is shunted out after the start-up stage.
Power Supply
The internal switching power supply generates the supply voltages for the connected servo units from
the intermediate circuit or from an external auxiliary voltage.
In addition, permanent monitoring is carried out of the temperature, the intermediate circuit voltage,
the supply voltages and the ballast function. In the case of inadmissible values, the system issues a
message that is further-processed appropriately.
The system indicates these messages to you directly by means of LEDs.
Ballast
When the drive is operating in regenerative mode, it feeds back to the intermediate circuit and raises
its voltage. If this voltage exceeds an impermissibly high value, the integrated ballast transistor
switches the ballast resistor (which can be external if desired) to the intermediate circuit and removes
the excess energy.

General Technical Data
BUG 3/2/20 Basic Feed Unit 7
Baumüller Nürnberg GmbH 5.96064.02
2.1.2 Block Diagram
Block Diagram of BUG Basic Unit
PE
L1
L2
L3
Additional
feed
Reset
Operating
indicator
TB H6 lights up red Uzk H5 lights up red +/- 15 V H4 lights up red TKK H3 lights up red
Error memory
Ballast resistor
overloading TB
Ballast ON for t > 1.5 s
Intermediate voltage,
Uzk, too high
(>400 V)
+/- 15 V controller
supply not OK
(< 12.5 V)
Temperature of
heatsink,
TKK, is too high
External ballast (option)
Ballast
resistor
Ballast control
Uzk > 375 V
Uzk > 400 V
Intermediate circuit
monitoring
Switching
power supply
+/- 15 V + 24 V (SELV)
X9: Controller supply
and communications
Ready for use
Green
Ready for use (SELV)
System
Error
Red
Intermediate circuit
L+
L-
Fan supplied
internally

Technical Data Electrical Data
8BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH
2.2 Electrical Data
Basic Feed Unit BUG 3 - 35 - 30 BUG 2 - 60 - 30 BUG 20 - 120 - 30
Connection voltage 1) 3 x 230 VAC +10 %/-15 % 50/60 Hz
Intermediate circuit power 10.5 kW 18 kW 36 kW
Intermediate circuit rated voltage 310 V
Rated current at TK= 45° C and TB= 45° C 35 A 60 A 120 A
Peak current for t ≤1 s 105 A 180 A 360 A
Peak starting current ION, 2)
Max. allowed for t ≤10 ms
300 A 700 A 1400 A
Controller supply 4) ±15 V/100 W
+24 V/10 mA
±15 V/200 W
+24 V/10 mA
Additional feed via transformer 230 V/160 VA
potential-free
230 V/250 VA
potential-free
Isolation transformer T2 1900 7153 1900 7176
Ballast resistor RB
peak power for t < 1.5 s
peak power for t < 1.8 s
internal (version B)
external (version E)
rated power
9 kW
16 Ω/190 W
≥16 Ω
As required
15 kW
9.4 Ω/400 W
≥8 Ω
As required
37 kW
4 Ω/900 W
≥4 Ω
As required
Power loss in rated operation without ballast 5) 110 W 200 W 280 W
Fan No Supplied internally Supplied internally
Environmental operating temp. range TB 6) 7) 0 ... 45 °C (with power reduction, 55 °C)
Coolant temperature range TK 6) 7) 0 ... 45 °C (with power reduction, 55 °C)
Power reduction 3 %/°C
Max. site altitude at rated loading
(see also char. curve 1 on page 9)
1000 m above sea level
Relative humidity 15 % - 85 % no condensation
Storage temperature range -30 °C ... +70 °C
Dimensions 100 x 250 x 230
mm
105 x 400 x 330
mm
157.5 x 400 x 330
mm
Weight 3 kg 9 kg 12 kg

Electrical Data Technical Data
BUG 3/2/20 Basic Feed Unit 9
Baumüller Nürnberg GmbH 5.96064.02
Remarks on the Technical Data
1) Connection voltage of the basic unit = secondary voltage U2of transformer T1.
Rated value: 230 V; never directly connect devices to the mains.
2) Max. permissible non-repetitive peak current (t < 10 ms) at switch-on; this is limited by the induc-
tivity of transformer T1on the input side and possible additional current limiting resistors, R2(refer
to the transformer layout); switch-on frequency: once per half hour.
3) Controller supply (switching power supply); the total of all the triggering power of all the BUS de-
vices may not exceed the power of the selected BUG unit's switching power supply!
4) Additional feed for the mains unit; useful when carrying out trouble-shooting with a test adapter
BU; the isolating transformer (T2) is specially matched to the mains unit; transformer T2is not
needed for operating the basic units.
5) Power losses of the devices; on one hand, this is important for rating the switching cabinet, and
on the other for rating the BUG basic unit:
ΣPV+ ΣPtomotor ≤PN(BUG) (see also Transformer Rating)
6) Coolant temperature measured 50 mm below the device according to DIN VDE 0160/DIN VDE
0558 Part 1; in rated operation, TKas well as TBmust be below the specified limit temperatures.
Otherwise, you must reduce the device's rated current.
7) Operating environment temperatures measured 300 mm away from the unit at the most, halfway
up the device according to DIN VDE 0160/DIN VDE 0558 Part 1; TBand TKmust not exceed the
specified limit temperature. The same conditions apply as before.
Characteristic curve 1: Load in dependence on the site elevation
0
10
20
30
40
50
60
70
80
90
100
Load [%]
0 1000 2000 3000 4000 5000
Installation height [m]
Load in dependence on
installation height

Technical Data Type Code
10 BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH
2.3 Type Code

Transportation, Unpacking
BUG 3/2/20 Basic Feed Unit 11
Baumüller Nürnberg GmbH 5.96064.02
3 TRANSPORTATION, UNPACKING
The units are packed at the factory in accordance with the order.
You should avoid jarring packages in transit or jolting them, e.g. when setting them down on the
ground.
After unpacking the package(s) and checking that the shipment is complete, you can start assembly.
Cardboard, cartridge paper and/or wood are used as packaging materials that can be disposed of
according to local regulations.
Report any damage in transit without delay.
DANGER
If the unit has been damaged in transit, do not connect it to the mains until appropriate high-voltage
testing has been carried out.
Ignoring this information can result in death, severe personal injury, or considerable damage to property.
Environmental conditions must be regulated according to pr EN 50178.

Transport, Unpacking
12 BUG 3/2/20 Basic Feed Unit
5.96064.02 Baumüller Nürnberg GmbH