Baumuller BUG 622 User manual

E5.94034.07a
Manual
Basic Supply Unit
BUG 622, 623

Titel Manual
Product Basic Supply Unit BUG 622, 623
Version 5.94034.07a
Copyright These operating instructions may be copied by the owner
in any quantity but only for internal use. For other purposes
these operating instructions and extracts thereof must not
be copied or reproduced.
Use and disclosure of information contained in these oper-
ating instructions are not permitted.
Designations and company marks contained in these op-
erating instructions may be brand names, the use of which
by third parties for their own purposes may violate the
rights of the holders.
Obligatory 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 lo-
cation these operating instructions must be passed on by
the owner together with the equipment/machine.
After any sale of the equipment/machine this original and
all copies must be handed over to the buyer. After disposal
or any other end of use this original and all copies must be
destroyed.
When the present operating instructions are handed over,
corresponding sets of operating instructions of a previous
version are automatically invalidated. Please notice that
specifications/data/information are current values ac-
cording to the printing date. These statements are not
legally binding according to the measurement, computa-
tion and calculations.
Baumüller Nürnberg GmbH reserves the right, in develop-
ing its products further, to change the technical specifica-
tions and the handling of the products concerned without
prior notice.
No liability can be accepted concerning the correctness of
the operating instructions unless otherwise specified in the
General Conditions of Sale and Delivery.
Manufacturer Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
D-90482 Nürnberg
Germany
Tel. [phone] - 0 Fax: [phone] - 1 30
www.baumueller.de

Basic Supply Unit BUG 622, 623 3
Baumüller Nürnberg GmbH 5.94034.07a
TABLE OF CONTENTS
Table of Contents
1 Safety Notes ........................................................................................................ 5
2 Technical data ..................................................................................................... 9
2.1 General ................................................................................................................................... 9
2.1.1 Function description ..................................................................................................................... 10
2.1.2 Block diagram .............................................................................................................................. 11
2.2 Electrical Data ...................................................................................................................... 12
2.3 Type code ............................................................................................................................. 15
3 Transport, Removal of Packaging .................................................................. 17
4 Assembly ........................................................................................................... 19
4.1 Dimensions ........................................................................................................................... 20
4.2 Assembly notes .................................................................................................................... 21
4.3 Attachment ........................................................................................................................... 22
5 Installation ......................................................................................................... 23
5.1 Hazard notes ........................................................................................................................ 23
5.2 Applicable standards ............................................................................................................ 24
5.3 EMC notes ............................................................................................................................ 26
5.4 Terminal diagram .................................................................................................................. 34
5.5 Connector pin assignment .................................................................................................... 37
5.5.1 Power terminals ........................................................................................................................... 37
5.5.2 Control terminals .......................................................................................................................... 39
5.6 Accessories .......................................................................................................................... 40
6 Commissioning ................................................................................................. 41
6.1 Danger information ............................................................................................................... 41
6.2 Operation .............................................................................................................................. 43
6.3 Mains failure ......................................................................................................................... 43
6.4 Messages and warnings ....................................................................................................... 44
6.5 Flow chart ............................................................................................................................. 46
7 Maintenance ...................................................................................................... 47
7.1 Maintenance information ...................................................................................................... 47
7.2 Environmental conditions ..................................................................................................... 48
7.3 Recommissioning ................................................................................................................. 48
7.4 Disposal ................................................................................................................................ 49
8 Appendix ........................................................................................................... 51
8.1 Manufacturer´s declaration ................................................................................................... 51
8.2 Declaration of Conformity ..................................................................................................... 52
8.3 General Conditions of Sale and Delivery .............................................................................. 53
8.4 Index ..................................................................................................................................... 56

Abbreviations
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ABBREVIATIONS
AC Alternating current
AM Asynchronous motor
a.m.s.l. above mean sea level
BBint ready (internal)
BBext ready (external)
BUC Baumüller Feed/Feed back Unit
BUG Baumüller Basic supply Unit
BUM Baumüller Mono Power Unit
BUS Baumüller Power Module
DC Direct current
DIN Deutsches Institut für Normung e.V.
(German Standardisation Authority)
EMC Electromagnetic compatibility
EN European Standard
FI Residual current
HS Main conductor
PE Protective earth
PELV Protective extra-low voltage
SELV Safe extra-low voltage
SM Synchronous motor
VBG Verwaltungs-Berufsgenossenschaft
(German professional trade association)
VDE Verband deutscher Elektrotechniker
(German Association of electrician)
ZK DC link

Safety Notes
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1 Safety Notes
Foreword
Relatively high leakage to earth occurs in the converter and the motor, i.e. the drive may be incompati-
ble with residual current protective devices. During operation, the principles on which the converter and
motor work, lead to leakage currents to earth which are dissipated via specified protective earth con-
nections and 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 makes a triggering of the higher-level current-operated e.l.c.b. more difficult or even impossible.
The connection of the current controller to the mains using only the current-operated e.l.c.b. is
prohibited (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 / 4.98, 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 to material assets.
It is only permitted to use the devices on earth-protected supply mains.
The discharge time of live parts is > 1 min. and depends on the connected DC link capacity.
This devices are not short-circuit-proof.
General Notes
This manual contains the necessary information for normal operation of the products described therein.
It is intended for technically-qualified personnel who are specially trained and are familiar in detail with
all warnings and maintenance tasks.
The units are finished to the highest standard and are safe and reliable. They can be installed and oper-
ated safely, and function without problem if the following cautionary notes in this manual are observed.
DANGER
Due to the nature of electrical equipment, certain parts of this unit carry dangerous voltage during
operation.
Serious injury and/or damage to property can result from non-compliance with these safety notes
and warnings.
Only qualified personnel familiar with the safety instructions, and instructions regarding assembly,
maintenance and operation are to work on this unit.

Safety Notes
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5.94034.07a Baumüller Nürnberg GmbH
Hazard notes
The terms used have the following definitions both within the scope of this handbook and in the notes
on the product itself:
Qualified Personnel
Qualified personnel, in the sense of the safety notes in this manual or on the products themselves, are
persons who are familiar with the installation, assembly, commissioning and operation of the product and
are correspondingly qualified, i.e.
yare trained or authorised to commission, earth and designate electrical circuits and appliances ac-
cording to the required safety standards.
yare trained or authorised in the care and operation of applicable safety equipment according to the
required safety standards.
The following notes are for your personal safety on the one hand, and on the other, the protection of
the described product or connected equipment from damage.
DANGER
This means that death, serious injury or considerable material damage will occur if the safety
precautions are not met.
WARNING
This means that death, serious injury or considerable material damage may occur if the safety
precautions are not met.
NOTE
This points to important information on the product, the manipulation of the product, or a particular
part of the documentation.

Safety Notes
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Baumüller Nürnberg GmbH 5.94034.07a
Normal use
Voltage test
BAUMÜLLER carries out a voltage test according to EN 50178 / VDE 0160 /4.98, Section 9.4.5 for
each unit.
Subsequent high-voltage tests must only be carried out by BAUMÜLLER NÜRNBERG GmbH.
WARNING
The unit/system may only be used as specified in the system handbook, and only with other units
and components recommended or approved by BAUMÜLLER NÜRNBERG GmbH.
Unauthorised conversion of the unit/system is not permitted for safety reasons.
The user is obliged to report any changes which may affect the safety of the unit/system immediately.
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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Technical Data
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2 TECHNICAL DATA
2.1 General
The basic units BUG 622 and BUG 623 are basic supply units for the DC link supply of the power mod-
ules BUS 62x.
For control tasks controller modules for Baumüller power units are available. Thus the units can adapted
to a wide variety of requirements.
There are two types of controller.
The BUS 6 V controller for highly demanding control tasks
BUS 6 M controller for highly demanding multi axis tasks
With the digital drive controllers of the BUS 6 series, both asynchronous and synchronous motors with
different encoder systems can be driven by the same unit.
The basic supply units are divided into two classes, 18 kW and 36 kW.
The basic supply units without return feed are designed for wide range voltage connection between
400 - 460 V (for units of development stages 000, 001, 100, 110) or 400 - 480 V (for all other develop-
ment stages) ±10 %, 50/60 Hz. Starting current load relief and DC link reactor are integrated into the
unit.
The basic supply units may contain a ballast circuitry to convert the drives brake energy. There are units
available in version E for connection of a external resistance (see type code).
An external extra low voltage 24 VDC (SELV / PELV) is neccessary for operating.

Technical Data
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2.1.1 Function description
yInput rectifier
The input rectifier is a non-controlled rectifier. To mains with a nomial voltage from 400 V to 460 V
(for units of development stages 000, 001, 100, 110) or 400 - 480 V (for all other development stag-
es) the unit can be connected without transformator and series reactor.
yStarting 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 restricted by a load relief
device.
To this purpose, a resistance is integrated into the DC link which restricts the charging current to a
maximum of 100 A (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 10 min.

Technical Data
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2.1.2 Block diagram

Technical Data
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2.2 Electrical Data
1. Voltage difference between phases must no exceed +/- 1 %.
Basic supply unit BUG 622 BUG 623
Connection voltage (Line) 1)
min. 3 x 400 VAC ±10 % 50 Hz
max. 3 x 460 VAC +10 % 50/60 Hz
(for units of development stages 000, 001, 100, 110, see type code)
or
max. 3 x 480 VAC +10 % 50/60 Hz
(for all other development stages)
Nominal input current 2) 28 A 56 A
Semi-conductor fuse (external) 3) 80 A 100 A
Nominal power 2) 18 kW 36 kW
Maximum power for 1 s (S6 40 %) 27 kW 54 kW
Nominal DC link voltage 2) 540 V DC
Total connectable capacitors in the DC link
(incl. supply unit) 2200 µF2200 µF
Capacitor in the DC link 500 µF750 µF
Switch on: Ready for use after ≤1,5 s ≤1,5 s
cycle time for connect the unit in circuit again 10 min
Low voltage supply 4) + 24 VDC −10 % +20 %
Power absorption (monitoring functions) 9 W 12 W
Ballast resistance RB
peak power output for t < 1.2 s internal
external (model external ballast) 5)
Ballast application at
18 kW
26 Ω / 300 W
>16 Ω/ power according require-
ments until nominal power
750 V
36 kW
16 Ω / 450 W
>16 Ω/ power according
requirements until nominal power
750 V
Power loss in nominal use without ballast 200 W 410 W
Operational environment temperature range TB0 ... 40 °C (with power reduction 55 °C)
Power reduction 3 % / °C
Installation height 6) 1000 m above sea level
Relative air humidity 15 % ... 85 % no dew
Storage temperature range -30 °C ... +70 °C
Short circuit proof not short circuit proof
Protection IP 20
Dimensions (BxHxD) 99 x 360 x 280 mm 132 x 360 x 280 mm
Weight 12 kg 16 kg

Technical Data
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2. Mains supply voltage ≠400 VAC, see characteristic curve 1, 2, 3 and 4
Characteristic curve 1: Load curve BUG 622 at TK= 25 °C
Characteristic curve 2: Power-/Voltage curve BUG 622 at TK= 25 °C
Characteristic curve 3: Load curve BUG 623 at TK= 25 °C

Technical Data
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Characteristic curve 4: Power-/Voltage curve BUG 623 at TK= 25 °C
3. see Accessories on page 40
4. 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 as well.
5.
6. Installation height > 1000 m see characteristic curve 6.
Characteristic curve 6: Load Values in relation to the installation height
WARNING
The minimal resistance must not fall below 16 Ω, otherwise the units could be damaged.
The power of the external ballast resistances is to be dimensioned on the machine.

Technical Data
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2.3 Type code

Technical Data
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Transport, Removal of Packaging
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3 TRANSPORT, REMOVAL OF PACKAGING
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.

Transport, Removal of Packaging
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Assembly
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4 ASSEMBLY
WARNING
The user is responsible for the assembly of the converter power unit, the motor, and the other com-
ponents according to applicable safety standards (e.g. DIN, VDE) and all other relevant national or
local regulations regarding conductor dimensions and fusing, grounding, circuit breakers, overcurrent
protection etc.
A space must be left above and below the units, and sufficient cool air and air circulation is to be pro-
vided, otherwise, the unit may be overheated
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 / 4.98, section 5.2.4.
Sheets of plastic covering the control electronics, the power stage and the device connection, addi-
tionally 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).
Pollution degree 3 and 4 according to EN 50178/VDE0160/4.98 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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4.1 Dimensions