Baumuller BUG 622, Manual

Page 1: ...E 5 94034 07a Manual Basic Supply Unit BUG 622 623 ...

Page 2: ...he 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 ...

Page 3: ... 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...

Page 4: ...er 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 assoc...

Page 5: ...se 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...

Page 6: ...ectrical circuits and appliances ac cording to the required safety standards y are 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 i...

Page 7: ... 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 co...

Page 8: ...Safety Notes 8 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH ...

Page 9: ...rs 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 ...

Page 10: ... without transformator and series reactor y 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 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 ...

Page 11: ...Technical Data Basic Supply Unit BUG 622 623 11 Baumüller Nürnberg GmbH 5 94034 07a 2 1 2 Block diagram ...

Page 12: ... link 500 µF 750 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...

Page 13: ...ürnberg GmbH 5 94034 07a 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 ...

Page 14: ...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 dimensio...

Page 15: ...Technical Data Basic Supply Unit BUG 622 623 15 Baumüller Nürnberg GmbH 5 94034 07a 2 3 Type code ...

Page 16: ...Technical Data 16 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH ...

Page 17: ...g 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 th...

Page 18: ...Transport Removal of Packaging 18 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH ...

Page 19: ...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 element...

Page 20: ...Assembly 20 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH 4 1 Dimensions ...

Page 21: ... left above and below the units and sufficient cool air and air circulation is to be provided y Coolant temperature 50 mm under the units up to 40 C With higher temperatures up to max 55 C power output of the units must be reduced by 3 per C y Do not locate any additional sources of heat above or below the units WARNING Inappropriate lifting can cause personal injury or damage to material assets Q...

Page 22: ...he mounting plate can be used as a mounting and drilling template The mounting plate of neigh boring units must be placed directly next to one another 2 Push back the plate spring and hang the unit in place The unit is then held fast between the mounting backplate and the back wall 3 To dismount the unit press the plate spring in direction back wall and lift out upwards ...

Page 23: ...ther relevant national or local regulations regarding conductor dimensions and fusing grounding circuit breakers overcurrent protection etc Relatively high leakage to ground occurs in the converter and the motor i e the drive may be incom patible with residual current protective devices EN 50178 1998 section 5 2 11 2 Variable speed drives may only be used if their use conforms to valid EN regulati...

Page 24: ...owing 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 converter to the mains using only the current operated e l c b is prohibited standard EN 50178 VDE 0160 4 98 sections 5 2 11 and 5 3 2 1 Concerning climat...

Page 25: ...term conductivity caused by condensation is possible y Overvoltage category III acc to IEC 664 1 Table 1 for air distances of mains circuits to their environments acc to EN 50178 VDE0160 4 98 Section 5 2 16 1 y Voltage range of the mains circuit for TN and TT mains acc to HD 384 4 4152 DIN VDE 0100 410 1996 with a phase to earth voltage of 500 V Insulating material IIIa for creepage distances acc ...

Page 26: ...o approx 600 MHz y high chopping rates and fast logic circuits electromagnetic field 16 MHz 1 GHz German EMC Law EMVG This converter corresponds to EMVG 6 Section 9 of EMVG German EMC Law dated 18 Sept 98 Devices which are exclusively manufactured or stocked as vendor parts or spare parts for further processing by industrial companies or craftsmen or by other specialists in the field of electromag...

Page 27: ...screen ing attenuation of the switch cabinets is sufficient see limit values of radio disturbance emissions according to EMVG german EMC law for your plant and the EMC inside the switch cabinet is guar anteed this you may presume when all project planning notes given in this chapter are observed the control leads may be mounted unshielded Also observe the items in Chapter Screening ...

Page 28: ...ategories should only cross at an angle of 90 y For symmetrical signal transmission e g differential amplifier inputs for the speed setpoint twist the conductors of each pair together and twist the pairs of wires together y The connection between converter and ground plate should be as short as possible 30 cm Use large cross sections 10 mm2 y Sources of noise such as fuses transformers chokes and ...

Page 29: ...dhesives etc from the ground connections If necessary use serrated lock washers DIN 6798 or similar measures to ensure a permanent conductive contact To prevent corrosion on ground connections use suitable metal combinations electrochemical series of metals and keep conductive electrolytes away from the connection by a protective coating e g grease y Always connect screens at both ends over a larg...

Page 30: ...ference on the ground system cannot be excluded totally However these are very rare if you observe the measures of the above chapters Cabling and Grounding The HF connection of a screen to ground can also be capacitive This prevents low frequent noise caused by earth loops Screen cables passing through different EMC areas must not be separated at the terminals otherwise the screening would be redu...

Page 31: ...Installation Basic Supply Unit BUG 622 623 31 Baumüller Nürnberg GmbH 5 94034 07a Proposal for the screen connection ...

Page 32: ...32 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH Shield clamps for grounding cable diameter mm Item no 2 x 2 6 mm 226752 3 8 mm 226741 4 13 5 mm 226745 10 20 mm 226749 larger diameters on request ...

Page 33: ...ilter next to the converter If the cables are longer than 30 cm screen the mains cable between converter and filter grounding at both ends y Input and output cables of the filter must be separated physically distance 30 cm y Connect the filter housing to ground over a large surface Leakage currents Due to the principle of operation stray capacitances in the filter power stage motor cable and motor...

Page 34: ...Installation 34 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH 5 4 Terminal diagram ...

Page 35: ...ccording to EN 60204 1 VDE0113 part 1 11 97 section 13 Laid see EMC notes If UL508C has to be observed Use 60 C 75 C copper conductors only UL508C Nov 27 1996 Tab 39 2 Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pound inches ZK ZK DC link connection of further power modules BUS 62x up to a total power rating of 18 kW BUG 622 or 36 kW BUG 623 If UL508C has to be observed Nominal...

Page 36: ...ors at its input which means on switching the 24 V supply charging cur rent is present The 24 V power supply is connected to the power modules BUS 62x thus the current input rises At continuous operation below 24 V the cooling power of the internal ventilator is reduced Power reduction of supply unit on request ...

Page 37: ...2 Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pound inches y ZK ZK Connect the servo power unit BUS 62x with the supply BUG 62x through the supplied connection When the unit leaves the factory the supplied connections rails are fastened to the frontrails of the BUS 62x M 6 terminals If UL508C has to be observed Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pou...

Page 38: ...6 terminals If UL508C has to be observed Use 60 C 75 C copper conductors only UL508C Nov 27 1996 Tab 39 2 Nominal tightening torque of the terminal screws 4 Nm resp 35 4 pound inches WARNING A resistance lower than 16 Ω are not permitted as this may cause damage to the equipment The power of the external ballast resistance depends on the motor and is not monitored by the unit ...

Page 39: ... unit in the line Recommended connection lead length 44 mm X 99 A X 99 B Terminal no Assignment 1 2 24 V PELV Terminal for power supply to the units both terminals internally bypassed 2nd terminal with power supply current 10 A 3 4 Ground 24 V PELV Terminal for power supply to the units both terminals internally bypassed 2nd terminal with power supply current 10 A 5 Ready for use internal PELV Rea...

Page 40: ...max 3 4 Forewarning SELV PELV Relay output Forewarning supply converter 24 V 0 5 A max 5 Reset with 24 V Signal SELV PELV Error message reset input of the supply converter potential free optocoupler input 8 15 mA 6 Ground reset SELV PELV Error message reset reference point of the supply converter potential free optocoupler input BUG 622 BUG 623 Semi conductor fuses Part no 80 A 1000 V 19008531 100...

Page 41: ...s on the unit the mains filter or the motor personal injury may be caused since the surface may carry hazardous voltage During operation the principles on which the converter and motor work lead to leakage currents to earth which are dissipated via specified protective earth connections and which may result in a current operated e l c b on the input side blowing prematurely A DC component in the f...

Page 42: ...lements located close to the equipment DIN VDE 0106 Part 100 Unfallverhütungsvorschrift Elektrische Anlagen und Betriebsmittel VBG4 Switch cabinet must have emergency stop facilities using which all voltages causing dangerous situ ations can be switched off This does not include equipment which if switched off would cause an other dangerous situation The releasing element for the emergency stop fa...

Page 43: ...99AB attach Terminal no 5 to 24 V Terminal no 6 to ground 24 V This corresponds to reset message memory y In the case of voltage failure DC link voltage lower than 300 V the basic supply unit generates the message voltage failure power error H2 y The supply unit s ready for use signal is taken away y The message voltage failure is deleted automatically if the mains voltage returns The supply unit ...

Page 44: ...l and external ready for use message if at least one phase is missing in the mains voltage y Phase failure monitoring H3 H5 H5 Warning The phase failure monitoring function recognises that a phase is missing in the supply voltage and gives an error message After 10 seconds the error is saved and an internal and external ready for use message is prevent ed y Temperatue monitoring H4 H5 H5 Warning T...

Page 45: ... is present Reset The error message memory of the supply unit is erased by operating the reset input supply 24 V at X99AB 5 and M24V at X99AB 6 optocoupler input without having to switch off the 24V auxiliary volt age supply funktion Speicher löschen flush memory Error saving can be cancelled by continual operation of the reset input if an automatic start e g after mains failure is to occur NOTE E...

Page 46: ...Commissioning 46 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH 6 5 Flow chart ...

Page 47: ...sed Do not begin work on the DC link or other parts of the power unit until you have made sure that neither potential nor voltage residual charge is applied When dismantling safety equipment during commissioning repair and maintenance ensure that the machine is take out of commission in accordance with applicable regulations Remount and check the safety equipment immediately after completing commi...

Page 48: ...e WARNING From six months storage period on the capacitors are destroyed during commissioning if they are not reformed beforehand Reform the capacitors by supplying the device ready for use for at least 48 hours with supply voltage but no impulse enable WARNING From six months storage period on the capacitors are destroyed during commissioning if they are not reformed beforehand Reform the capacit...

Page 49: ...beryllium dust set free when the components are opened is dangerous to your health The units and modules must be recycled at the end of their service life If recycling is not possible dispose the units and modules according to the national regulations and the regional and local ordinances Component Material Housing Sheet steel aluminium Chokes Copper transformer magnetic sheet steel Various spacer...

Page 50: ...Maintenance 50 Basic Supply Unit BUG 622 623 5 94034 07a Baumüller Nürnberg GmbH ...

Page 51: ...gestellt wurde dass die Maschine in die diese Komponente eingebaut ist den Bestimmungen der EG Maschinenrichtlinie 89 392 EWG Anhang II B entspricht We herewith declare that this delivery includes the following specified machine component and that its putting into operation is prohibited until the declaration is made that the machine in which this compo nent is built in complies with the regulatio...

Page 52: ...eichnung Specification of the machine component Type Basic Supply Unit BUG 622 623 BUG 62 Die Übereinstimmung des bezeichneten Produkts mit den Vorschriften der Richtlinie wird nachgewie sen durch die Einhaltung folgender Normen Conformity of the significated product with the guidelines will be proved by following rules EN 50178 1994 VDE 0160 11 94 Ausrüstung von Starkstromanlagen mit elektronisch...

Page 53: ... problems in procuring materials official directives also apply as force majeure irrespective of whether they arise with regard to Baumüller or suppliers c In these cases Items 4 a b the purchaser shall have no claim to compensation due to non fulfilment or delay of the delivery 5 Packaging Items for sale and delivery items are packaged and transport insurance policies are taken out according to t...

Page 54: ...t the reserved goods are bundled or sold with other items standing in the possession of third parties then the assignment shall only apply to the amount of the invoice value of the reserved goods The purchaser is authorised to collect these assigned claims Upon request he she has to make notice of the assignment to the debtor c The purchaser shall inform Baumüller without delay of impending and en...

Page 55: ...idered as having been declared and the orderly performance of the contract as having been ascertained d The agreed service shall be considered as having been accepted when the item delivered has been put into operation by the purchaser himself herself or upon his her instructions by third parties beyond the functional test required to carry out the acceptance This also applies in the event that th...

Page 56: ...ion 10 Fuses 40 G Grounding 29 I Input rectifier 10 Installation 23 Installation height 12 L Leakage currents 33 Leitungsschutzsicherung 35 Low voltage supply 12 M Mains failure 43 Maintenance 47 Maintenance information 47 Messages 44 P Pollution degree 19 Power loss 12 Power reduction 12 R Recommissioning 48 Removal of packaging 17 S Safety notes 5 Semi conductor fuse 35 Shielding 30 Sources of h...

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Page 58: ... our permanent revision service 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 Before you make any information given in this manual to the basis of your own calculations and or applications please make sure that you have the latest edition of the ...