Instruction Handbook: English

Instruction handbook
Language English
Translation
Document No. 5.01032.05
Part No. 343509
Status 2013-03-13
Mono Power Unit /

Power Module
BUM 60 / BUS 60
E 5.01032.05 Read the Instruction handbook before starting any work!

Copyright These Instruction handbook may be copied by the owner in any quantity, but only for internal
use. This Instruction handbook may not be copied or reproduced, in whole or in part, for any
other purposes.
The use and disclosure of information contained in these Instruction handbook are not per-
mitted.
Designations and company marks contained in these Instruction handbook could be trade-
marks, the use of which by third parties for their own purposes could violate the rights of the
rights holder.
Preliminary information
Warning: Insofar as this document is identified as being preliminary information, the follow-
ing applies:
this version is regarded as providing advance technical information to users of the described
devices and their functions at an early enough time in order to adapt to any possible changes
or expanded functionality.
This information must be regarded as being preliminary, as it has not yet passed through
Baumüller's internal review process. In particular, this information is still subject to changes,
thus no legal liability can be derived from this preliminary information. Baumüller assumes no
liability for damages that might arise from this possibly faulty or incomplete version.
If you detect or suspect any content errors and/or major form errors in this preliminary infor-
mation, we request that you notify the Baumüller support specialist responsible for you.
Please provide us, via this employee, with your insights and comments so that we can take
them into account and include them when transitioning from the preliminary information to
the final information (as reviewed by Baumüller).
The conditions stipulated in the following section under "Obligatory" are invalid in case of pre-
liminary information.
Obligatory These Instruction handbook are a part of the equipment/machine. These Instruction hand-
book must be available to the operator at all times and must be in legible condition. If the
equipment/machine is sold or moved another location, these Instruction handbook 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 use, this original and all copies must be destroyed.
When the present Instruction handbook are handed over, corresponding sets of operating in-
structions of a previous version are automatically invalidated.
Please note that the specifications/data/information are current values according to the
printing date. These statements are not legally binding with regard to measurements,
computation or calculations.
Baumüller Nürnberg GmbH reserves the right, in developing its products further, to change
the technical specifications and handling of it products concerned without prior notice.
No liability can be accepted concerning the correctness of these Instruction handbook unless
otherwise specified in the General Conditions of Sale and Delivery.
© Baumüller Nürnberg GmbH

Ostendstr. 80 - 90
90482 Nuremberg
Germany
Tel. +49 9 11 54 32 - 0
Fax: +49 9 11 54 32 - 1 30
Email : [email protected]
Internet: www.baumueller.de
Table of Contents
1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information on the instruction handbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Limitation of liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Copyright protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Guarantee provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Contents of the instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Usage for the intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Protective devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.11 Conduct in case of danger or accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.12 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3.1 System types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3.2 Requirements to the energy supply / supply system . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.3 Environmental requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Design and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1.1 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.2 Block diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Instruction handbook BUM 60 / BUS 60 3

Document No.: 5.01032.05 of 82
Table of Contents
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3 Transport inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.2 Preparing for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2.1 Drilling patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.3 Requirements to the supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4 Requirements to the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.5 Protection of the device and the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.6 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.7 Installation requirements with regard to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8 Operating sequence of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.9 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.9.1 Connection diagram BUM 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.9.2 Connection diagram BUS 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.10 Connection information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.11 Terminal and pin assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.11.1 Power terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.11.2 Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.12 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Messages and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.3.1 Monitoring facilities of the feed current converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.3.2 Monitoring on motor-end inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.2 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.3 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.3.1 Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Instruction handbook BUM 60 / BUS 60

of 82 Document No.: 5.01032.05 Baumüller Nürnberg GmbH
Table of contents
10 Shutdown, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.2 Disposal facilities/authorities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Appendix B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

B.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Table of Contents

1 GENERAL
1.1 Information on the instruction handbook
These instruction handbook provides important information on handling the device. A prerequi-
site for safe work is compliance with all specified safety notes and procedural instructions.
Additionally, the valid accident prevention regulations and general safety regulations applicable
to the scope of application the device must be complied with.
Read the instruction handbook, particularly the safety notes chapter, completely before begin-
ning any work on the device. The instruction handbook is part of the product and must be kept
accessible to personnel at all times in the immediate vicinity of the device.

1.2 Key to symbols
1.2 Key to symbols
Warning
notes
Warning notes are identified by symbols in these instruction handbook. The notes are intro-
duced by signal words that express the extent of the danger.
It is imperative that these notes be complied with and are conscientiously regarded in order to
prevent accidents, personal injury and material damage.
DANGER!
....points out an immediately dangerous situation that will lead to severe injuries or
death if not avoided.
WARNING!
....points out a potentially dangerous situation that could lead to severe injuries or
death if not avoided.
CAUTION!
....points out a potentially dangerous situation that could lead to minor or slight inju-
ries if not avoided.
NOTICE!
....points out a potentially dangerous situation that could lead to material damage if
not avoided.
Recommen-
dations
NOTE!
....highlights useful tips and recommendations, as well as information for efficient and
problem-free use.

General 1
1.3 Limitation of liability
All specifications and notes in these instruction handbook were compiled taking into account the
applicable standards and regulations, the state of the art and our knowledge and experience of
many years.
The manufacturer assumes no liability for damages due to:
m noncompliance with the instruction handbook
m usage for other than the intended purpose
m usage by untrained personnel
The actual scope of delivery can vary in case of optional equipment, laying claim to additional
order options, or on account of the latest technical changes to the explanations and represen-
tations described herein.
The user bears the responsibility for performing service and initial operation in accordance with
the safety regulations of the applicable standards and all other relevant governmental or local
regulations concerning the dimensioning and protection of conductors, grounding, disconnec-
tors, overcurrent protection, etc.
The person who carried out the mounting or installation is liable for any damage incurred when
assembling or connecting the device.
1.4 Copyright protection
The instruction handbook must be treated confidentially. It is to be used exclusively by person-

nel who work with the device. The consignment of the instruction handbook to third persons
without the written permission of the manufacturer is prohibited.
NOTE!
The specific contents, text, drawings, images and other representations are copy-
righted and subject to industrial property rights. Any prohibited usage is punishable
by law.
1.5 Other applicable documents
Components of other manufacturers are integrated into the device. For these purchased parts,
hazard assessments have been performed by the respective manufacturers. The compliance of
the design construction with the applicable European and national regulations has been de-
clared for the components by the respective manufacturers.

1.6 Spare parts
1.6 Spare parts
WARNING!
False or flawed spare parts can lead to damage, malfunction or complete fail-
ure, thus endangering safety.
Therefore:
m Only use original spare parts of the manufacturer.
Procure spare parts through an authorized dealer or directly from the manufacturer.
1.7 Disposal
Insofar as no take-back or disposal agreement has been made, please disassemble units cor-
rectly and properly recycle the constituent parts.
See also ZDisposal– ab Seite 69.
1.8 Guarantee provisions
The guarantee provisions are stated in a separate document of the sales documents.
The devices described herein may only be operated in accordance with the stipulated methods,
procedures and conditions. Anything else not presented here, including the operation of devices
in mounted positions, is not permitted and must be cleared with the plant on a case-by-case ba-
sis. If the devices are operated in any other manner than as described within these instruction
handbook, then all guarantee and warranty rights are rendered null and void.
1.9 Customer service
Our customer service is available to provide you with technical information.

Info on the responsible contact persons is available at all times via telephone, fax, mail or the
Internet.
1.10 Terms used
The term „device“ or the item designation BM5XXX are also used in this documentation for this
Baumüller product. A list of the abbreviations used can be found in ZAppendix A - Abbrevia-
tions– ab Seite 73.

2SAFETY
This section provides an overview of all of the important safety aspects for optimum protection
of personnel as well as for the safe and problem-free operation.
2.1 Contents of the instruction handbook
Each person who is tasked with performing work on or with the device must have read and un-
derstood the instruction handbook before working with the device. This also applies if the person
involved with this kind of device or a similar one, or has been trained by the manufacturer.
2.2 Changes and modifications to the device
In order to prevent hazards and to ensure optimum performance, no changes, additions or mod-
ifications may be undertaken on the device that have not been explicitly approved by the man-
ufacturer.

2.3 Usage for the intended purpose
2.3 Usage for the intended purpose
The device is conceived and constructed exclusively for usage compliant with its intended pur-
pose described in these instruction handbook.
The devices of the model series Mono Power Unit / Power Module BUM 60 / BUS 60 are either
mains rectifier or active mains rectifier in combination with axis units with servo controller. De-
vices are also available in graduated design size and performance classes.
The device Mono Power Unit / Power Module BUM 60 / BUS 60 is used exclusively as a con-
verter for controlling a motor.
A device is considered as being used compliant with its intended purpose if all notes and infor-
mation of these instruction handbook are adhered to.
WARNING!
Danger arising from usage for an unintended purpose!
Any usage that goes beyond the intended purpose and/or any non-compliant use of
the device can lead to dangerous situations.
Therefore:
m Only use the device compliant with its intended purpose.
m Observe all specifications of these instruction handbook.
m Ensure that only qualified personnel work with/on this device.
m When configuring, ensure that the device is always operated within its specifica-
tions.
m Mount the device on a wall that can sufficiently bear the load.
m The device must always be operated within a control cabinet.
m Ensure that the power supply complies with the stipulated specifications.
m The device may only be operated in a technically flawless condition.
m Only operate the device in combination with components approved by Baumüller
Nürnberg GmbH.
m The device has been developed in such a manner that it fulfills the requirements
of the category C3 according to IEC 61800-3:2005.
m The device is not intended to be connected to the public power supply system. To
operate the device in primary surroundings of the category C2/C1 (residential,
business and commercial areas, directly on a public low-voltage power supply
without an intermediate transformer), special measures to reduce the transient
emissions (line-internal and radiated) must be provided for and certifiable by the
system builder. Otherwise, EMC interference could occur without such additional
measures.

Safety 2
2.4 Responsibility of the operating company
The device will be used in commercial areas. Thus, the proprietor of the device is subject to the
legal work safety regulations.
Along with the notes on work safety in these instruction handbook, the safety, accident preven-
tion and environmental protection regulations valid for the area of application of this device must
be complied with. Whereby:
m The operating company must inform himself about the applicable work health and safety reg-
ulations and ascertain, in a hazard assessment, any additional hazards that could arise from
the special working conditions in the use area of the device. These must then be implemented
in the form of instruction handbook for operation of the device.
m These instruction handbook must be kept accessible to personnel working with the device at
all times in the immediate vicinity of the device.
m The specifications of the instruction handbook must be adhered to completely and without ex-
ception.
m The device may only be operated in a technically faultless and operationally safe condition.
2.5 Protective devices
The devices BUM 60 / BUS 60 comply with the protection class IP 20.
All devices BUM 60 / BUS 60 must be installed in an appropriate control cabinet to meet the
protection classification required in EN 61800-5-1, chapter 4.2.3.3.
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted.
Therefore:
m The device must be in operated inside of a control cabinet that provides protection
against direct contact of the devices and at least meets the requirements of
EN 61800-5-1, Chapter 4.2.3.3.

2.6 Training of the personnel
2.6 Training of the personnel
WARNING!
Risk of injury due to insufficient qualifications!
Improper handling can lead to significant personal injury and material damage.
Therefore:
m Certain activities can only be performed by the persons stated in the respective
chapters of these instruction handbook.
In these instruction handbook, the following qualifications are stipulated for various areas of ac-
tivity:
m Operating personnel
n The drive system may only be operated by persons who have been specially trained, fa-
miliarized and authorized.
n Troubleshooting, maintenance, cleaning, maintenance and replacement may only be per-
formed by trained or familiarized personnel. These persons must be familiar with the in-
struction handbook and act accordingly.
n Initial operation and familiarization may only be performed by qualified personnel.
m Qualified personnel
n Electrical engineers authorized by Baumüller Nürnberg GmbH, and qualified electricians
of the customer or a third party who have learned to install and maintain Baumüller drive
systems and are authorized to ground and identify electrical power circuits and devices in
accordance with the safety engineering standards of the company.
n Qualified personnel have had occupational training or instruction in accordance with the
respective locally applicable safety engineering standards for the upkeep and use of ap-
propriate safety equipment.

Safety 2
2.7 Personal protective equipment
The wearing of personal protective equipment is required when working in order to minimize
health and safety risks.
m The protective equipment necessary for each respective type of work shall always be worn
during work.
m The personal safety signs present in each working area must be observed.
Protective work clothing

should be snug-fitting work clothes, with low tearing resistance, narrow sleeves and
with no extending parts. It serves to primarily protect against...
No rings or chains should be worn.
Hard hat
to protect against falling down and flying around objects.
Safety shoes
to protect against heavy objects falling down.
Protective gloves
to protect hands against friction, abrasion, puncturing or more severe injuries, as well
as contact with hot objects.
Wear for
special
work.
Protective eye wear

to protect the eyes against flying around objects and sprayed liquids.

2.8 Special hazards
2.8 Special hazards
In the following section, the remaining marginal risks will be stated that have been identified as
a result of the hazard analysis.
Observe the safety notes listed here and the warning notes in the further chapters of this Instruc-
tion handbook to reduce health risks and dangerous situations.
Electrical
current
DANGER!
There is an immediate risk of fatal injury if live electrical parts are contacted. Damage
to the insulation or individual components can be life-threatening.
Therefore:
m Switch off the electrical power immediately in case of damage to the power supply
insulation.
m Only allow work on the electrical system to be performed by qualified personnel.
m Switch off the current when any kind of work is being performed on the electrical
system and ensure safety before switching on again.
Danger from
residual en-
ergy
DANGER!
Stored electric charge.
Discharge time of the system = discharge time of the device with the longest DC link
discharge time.
Therefore:
m Do not touch electrically live parts before taking into account the discharge time of
the capacitors.
m Pay attention to the corresponding notes on the device.
m If additional capacitors are connected to the DC link, the DC link discharge can
take a much longer time. In this case, the necessary waiting period must itself be
determined or a measurement made as to whether the equipment is de-energized.
This discharge time must be posted, together with an IEC 60417-5036 (2002-10)
warning symbol, on a clearly visible location of the control cabinet.

Safety 2
Moving
components
WARNING!
Risk of injury from moving components!
Rotating components and/or components moving linearly can result in severe injury.
Therefore:
m Do not touch moving components during operation.
m Do not open any covering during operation.
m The amount of residual mechanical energy depends on the application. Powered
components still turn/move for a certain length of time even after the power supply
has been switched off. Ensure that adequate safety measures are taken.
2.9 Fire fighting
DANGER!
There is a risk of electric shock if an electrically-conductive, fire-extinguishing agent
is used.
Therefore:
m Use the following fire-extinguishing agent:
ABC powder / CO2

2.10 Safety equipment
2.10 Safety equipment
WARNING!
Risk of fatal injury due to non-functional safety equipment!
Safety equipment provides for the highest level of safety in a facility. Even if safety
equipment makes work processes more awkward, under no circumstances may they
be circumvented. Safety can only be ensured by intact safety equipment.
Therefore:
m Before starting to work, check whether the safety equipment in good working order
and properly installed.
2.11 Conduct in case of danger or accidents
Preventive m Always be prepared for accidents or fire!

measures m Keep first-aid equipment (e.g. first-aid kits, blankets, etc.) and fire extinguishers readily ac-
cessible.
m Familiarize personnel with accident alarm, first aid and rescue equipment.
And if some- m Stop operation of the device immediately with an EMERGENCY Stop.
thing does m Initiate first aid measures.
happen: re-
m Evacuate persons from the danger zone.
spond prop-
erly. m Notify the responsible persons at the scene of operations.
m Alarm medical personnel and/or the fire department.
m Keep access routes clear for rescue vehicles.

Safety 2
2.12 Signs and labels
The following symbols and information signs are located in the working area. They refer to the
immediate vicinity in which they are affixed.
WARNING!
Risk of injury due to illegible symbols!
Over the course of time, stickers and symbols on the device can become dirty or oth-
erwise unrecognizable.
Therefore:
m Maintain all safety, warning and operating labels on the device in easily readable
condition.
Electrical voltage
Only qualified personnel may work in work areas that identified with this.
Unauthorized persons may not touch working materials marked correspondingly.
DANGER!
discharge time.
Therefore:
the capacitors.

Figure 1: Signs

Safety 2
Wechselstromumrichter
Typ: BUM60-1224-54-B-001-VC-0E-0001-0014-0000
Eing.: 3x400-480V AC -/+10% 50/60 Hz Ausg.: 3x0-380V AC 3x12 Aeff, 0-300Hz
BA.: GKB 200% 2e
Ser.Nr. 123456789 Art.Nr. 00376239
Figure 2: Type plate


3 TECHNICAL DATA
3.1 Dimensions
The following dimension drawings show the main dimensions of the devices. By means of the
dimension drawings the space requirements within the control cabinet are determined. The di-
mension drawings in ZDrilling patterns– from page 40 must be used in order to do the required
drillings / segments.
NOTE!
All dimensions in mm.
Figure 3: Dimensions

3.2 Weight
3.2 Weight
Weight without controller cassette ca. 7 kg
3.3 Operating requirements
3.3.1 System types
There are three basic types of the current supply systems regarding the grounding, which con-
form with DIN VDE0100 part 300 and IEC 60364:
m The TN system has a directly grounded point (system grounding). The cabinet of the electrical
installation is connected via the protective conductors and PE conductors with this point.
m The TT system has a directly grounded point (system grounding). The cabinet of the electrical
installation is connected with grounding electrodes. The grounding electrodes are separated
from system grounding.
m The IT system has no direct connection between the active conductors (L1, L2, L3, N) and
grounded parts (PE). The cabinet of the electrical installation is grounded. The separation is
reached by using an isolating transformer or an independent current source (generator, bat-
tery).
Supported system types
NOTICE!
The operation of the BUM 60 / BUS 60 is possible at TN / TT systems, only.

Technical Data 3
3.3.2 Requirements to the energy supply / supply system
Supply system Industrienetz mit hart- oder niederimpedant

(see ZSystem types– from page 24) geerdetem Sternpunkt (TN-Netz oder TT-Netz)
Inductance min. uk = 0,4 % max. uk = 4 %
(sum of power supply inductance and choke inductance)
Rated power supply voltage/frequency device 1) (UAC) 3 x 400 V
50/60 Hz
Absolute minimum supply voltage device1) (UAC) 3 x 207 V / 50/60 Hz
Absolute maximum supply voltage device1) (UAC) 3 x 528 V / 50/60 Hz
Absolute minimum frequency 3) 47 Hz
Absolute maximum frequency 3) 63 Hz
Harmonics (power supply voltage) THDU b 10 %
EN 61800-3, chap. 5.2.1, class 3
Unbalanced power supply voltage max. 3 %

EN 61000-2-4, tab. 1, class 3
Voltage variations/-fluctuations +/-10 %

EN 61200-2-4, class 3 +10 % to -15 % at a period of b 1 min
Control voltage 2) (UDC) + 24 V +/-10 %
EN 61131-2:1994, table 7
1) Rated voltage is 400 V.

With lower supply voltages the output power of the device is reduced.
2) The control voltage must accord to PELV (EN 61800-5-1, chapter 3.21) or SELV (EN 61800-5-1, chap. 3.35).
At control voltage of < 24 V the ventilation power output is reduced. Therefore, it may be necessary, to reduce the output currents as
well.
If you comply with UL 508C the current is limited to 4 A with fuses according UL 248 and the voltage is limited to max. 30 VDC.
3)
Rate of change of the power supply frequency 1 Hz/s at a maximum (EN 61000-2-4, class 3).

3.3 Operating requirements
3.3.3 Environmental requirements
Transport temperature range - 25 °C bis + 70 °C

Transport climatic category 2K3
EN 60721-3-2
Storage temperature range - 25 °C bis + 55 °C

Storage climatic class 1K4
EN 60721-3-1
Operation environment Industrial system 3)

Operation temperature range 1) min. 5 °C to max. 45 °C
(with power derating 3 %/ °C) up to 55 °C))
Operation climatic class 3K3
EN 60721-3-3
Mounting height 2) absolute altitude up to 1000 m

Humidity (operation) relative humidity: 5 % to 85 % no condensation
EN 60721-3-3 and
absolute humidity: 1 g/m3 to 25 g/m3
Ionizing and non-ionizing radiation < measurable range
1)
The environmental temperature is measured as follows:
y determine several measurement points, that cover
the entire marked range with a space of 10 cm
y measure the temperature at this measurement points
The highest value represents the

environmental temperature!
2)
Loading values in dependence on the mounting height for altitudes greater than 1000 m
3) For the operation in an environment of category C2 according to IEC 61800-3:2005, additional measures may be required.The manu-
facturer of the installation / user must provide the following evidence in this case: The additional measures are effective. The specified
limit values of category C2, which are described in IEC 61800-3, are complied with.

Technical Data 3
NOTICE!
Normally, non-conductive pollution occurs. Conductive pollution is unacceptable.
Conductive pollution can lead to the destruction of the device. The customer is re-
sponsible for destructions, which were caused by pollution due to conductive materi-
als or components.
3.4 Electrical data
3/6 3/6 - 54 - 6/12 6/12 - 54 - 8/16 12/24

x - xx6 x - xx6
Connection voltages 1) 3 x 400 - 480 VAC 50 - 60 Hz, ± 10 %
Semiconductor fuses (external) 8) 16 A
Type of protection IP 20
2)
Rated DC Link voltage 540 VDC
DC Link capacitor 110 µF 330 µF 110 µF 330 µF 220 µF 220 µF
Switch-on:
≥ 1,5 s
Ready for operation after
Frequency to switch on power sup- unlimited
ply 12)
Output voltage 9) 10) 3 x 0 VAC ... 95 % of input voltage
Output power 3) 10) 2 kVA 2 kVA 4,5 kVA 4,5 kVA 6 kVA 8 kVA
Typical motor power 3) 1,1 kW 1,1 kW 2,25 kW 2,25 kW 3 kW 4,5 kW
4) 5) 10) 11)
Rated output current 3 Aeff 3 Aeff 6 Aeff 6 Aeff 8 Aeff 12 Aeff
Peak output current 4) 5) 6) 10) 6 Aeff 6 Aeff 12 Aeff 12 Aeff 16 Aeff 24 Aeff
Low-voltage supply +24 VDC ± 10 % (max. 55 W)
Ballast resistor RB (only BUM 60)
Peak power of ballast resistor 10 kW / 1 s
Continuos output 250 W
External ballast resistor 7) min. 60 Ω
Max. switch-on time / ratio 1,5 s / 1 : 33
Power loss in rated operation,
without low-voltage supply, 60 W 60 W 110 W 110 W 130 W 170 W
without ballast
WARNUNG!
With a single-phase connection, neither of the two lines must have ground potential!

3.4 Electrical data
1)
Single-phase connection possible. Voltage difference between phases must not exceed +/- 3,0 %
2) All nominal values refer to a connection voltage of 400 V
With a single-phase connection, the rated DC link voltage is reduced by 35 %
3) With a single-phase connection, the value is reduced by 66%
4) With a single-phase connection, the value is reduced by 50%
5)
The current information depends on the controller type
Digital controller: effective value for sinus commutation
6)
For a maximum of 200 ms without preloading using E/V-controller
For a maximum of 1 s without preloading using V-controller
The load cycle must be dimensioned, that the effective value of the output current does not exceed the rated current.
7) If UL508C has to be observed: the external ballast resistor must protect itself from overheating.
8)
Do use fuses, which have a I2t-value at the working point of max. 510 A2s .
If UL508C has to be observed: do use fuses 32A/1000V: 3NE4 101 manufactured by Siemens (Item-No. 101 940 Baumüller). The cor-
responding fuse-carrier is available from Baumüller (Item-No. 101 960). You may even use UL-approved fuses listed in the table below.
In the table below we have listed UL-approved fuses and fuses that are not UL-approved. Please observe, that the listed fuses are of
different design and that you have to use corresponding fuse-carriers. Not all fuses listed below can be inserted into the above listed
fuse-carrier from Baumüller!
Full range fuses (semiconductor and line protection)

Bussmann 00 16A/690V: 170M2692 20A/690V: 170M2693 25A/690V: 170M2694 32A/690V: 170M2695
40A/690V: 170M2696
Gould 0 40A/690V: A0-69E40 D8 50A/1250V: A0-125E50 D1
SIBA 00 16A/690V: 2047734-16 20A/690V: 2047734-20 25A/690V: 2047734-25
Siemens 000 16A/690V: 3NE1 813-0 20A/690V: 3NE1 814-0 25A/690V: 3NE1 815-0
00 20A/660V: 3NE8 714 25A/660V: 3NE8 715 25A/660V: 3NE8 015 25A/690V: 3NE8 015-1
32A/660V: 3NE8 701 35A/660V: 3NE8 003 35A/690V: 3NE8 003-1
0 32A/1000V: 3NE4 101 40A/1000V: 3NE4 102
size bold: no UL
9)
The output voltage is a pulse-commutated DC. The setting range refers to the r.m.s. value of the fundamental wave.
10)
R.m.s. value at an ambient temperature of 45 °C.
11) The rated output current must be reduced between 45 °C and 55 °C. The rated output current is calculated according the following
formula::
I A = I A ( 45°C ) ⋅ ⎛ 1 – environmental temperature – 45°C- ⋅ 0, 03⎞

-----------------------------------------------------------------------------------------------
⎝ °C ⎠
For example: rated output current = 30 A, environmental temperature = 47° C:
I A = 30A ⋅ ⎛ 1 – ⎛ ---------------------------------- ⋅ 0, 03⎞ ⎞ = 30A ⋅ 0, 94

47°C – 45°C
⎝ ⎝ °C ⎠⎠
The output current must be reduced to: 28,2 A

12)
A minimum break time after switch-off of 2 min.must be observed.

Technical Data 3
NOTE
The use of the commutating choke BK3-0025/0030, Inom = 25 A, L = 1,18 mH with
copper busbar part no. 368377 or with terminals part no. 399136 is recommended, if
the device BUM60-12/24 operates at full capacity.
Reason:
The ripple current through the DC link capacitor is high, if the device operates at full
capacity. The current can be reduced by connecting ahead a commutating induc-
tance accordingly the DC link capacitor load is reduced and therefore is heated up to
a lesser extent and a longer live cycle of the DC link capacitors can be expected than
by operating the device on the power limit without using a commutating choke.

3.4 Electrical data

4DESIGN AND OPERATION
4.1 General
The single power unit BUM 60 and the power module BUS 60 complement the Baumüller Mod-
ular System in the medium performance range.
Plug-in V-controller cards are supposed to be used for closed-loop control. All V-controller com-
binations up to three printed circuit levels can be used.
HINWEIS!
The controller is fitted as plug-in card and the description, which is available sepa-
rately, contains the respective properties and technical data.
The single power unit BUM 60 consists of the feed current converter on the power supply side
and the motor-end inverter.
The power module BUS 60 consists only of the motor-end inverter. The power supply is con-
nected via the DC link.

4.1 General
4.1.1 Description of function
The whole unit BUM 60 consists of the three parts feed current converter on the power supply
side, motor-end inverter and controller plug-in card. This documentation does not refer to the
available controllers. Each controller comes with its own documentation.
f Feed current converter on the power supply side
The feed current converter is an non-controllable B6 rectifier with starting current load relief
and ballast circuit.
f Starting current load relief
A direct switch-on of the unit would lead to an inadmissibly high level of impulse current, be-
cause of the DC link capacity without starting current load relief. To avoid this impulse current,
the starting current is limited by a resistor.
f Ballast circuit
In certain operation modes feeds the motor energy to the unit. This energy is stored and leads
to a higher DC link voltage. To avoid reaching the over voltage switch-off threshold, the feed-
back energy is transformed to heat in an internal or external ballast resistor.
f Motor-end inverter
The motor-end inverter comprises the IGBT power unit and the accompanying detectors. The
detectors supply on the one hand measurement signals and on the other hand the self-pro-
tection facilities of the power electronic.
The control of the inverter is run by the controller.
The power module BUS 60 does not include the parts feed current converter with starting load
relief and ballast circuit. The unit consists only of the motor-end inverter and the controller plug-
in.
With this power module - in connection with units, containing feed current converters - multi axle
systems can be built, that enable a power transfer via the DC link.

Design and Operation 4
4.1.2 Block diagrams
Figure 4: Block Diagram BUM 60 - XX/XX - 54 - X - XXX

4.1 General
Figure 5: Block diagram BUS 60 - XX/XX - 54 - X - XXX

5TRANSPORT AND PACKAGING
5.1 Safety notes for transport
NOTICE!
Damage due to unauthorized transport!
Transport handled by untrained personnel can lead to a substantial amount of mate-
rial damage.
Therefore:
m The unloading of the packages upon delivery as well as the in-house transport
should only be done by trained personnel.
m Contact Baumüller Nürnberg GmbH sales office if necessary.
WARNING!
Danger of mechanical hazard!
Secure devices against falling down.
Therefore:
m Use appropriate handling material.
5.2 What to observe when transporting
For initial transport of the device, it is packed at the manufacturer. If the device is to be further
transported, ensure that the following conditions are met throughout the entire transport:
m Climate class 2 K 3 as per EN 60721-3-2
m Temperature range - 30 °C up to + 70 °C
m Vibration, shock, continuous shock class 2 M 1 as in EN 60721-3-2

5.3 Transport inspection
5.3 Transport inspection
Upon receiving the delivered goods, immediately examine them for completeness and transport
damage.
If there is outwardly visible transport damage, proceed as follows:
m Do not accept the delivery or conditionally accept it with reservations.
m Note the extent of the damage on the transport documents or on the delivery note of the trans-
port agent.
m Immediately file a complaint with the freight carrier. Have the complaint confirmed in writing
and immediately contact the responsible representative of Baumüller Nürnberg GmbH.
NOTE!
The device may not be operated if there is visible transport damage!
5.4 Unpacking
After having received the still packaged device:

h Avoid transport shocks and hard jolts, e.g. when putting an item down.
If no transport damage is visible:

h Open the packaging of the device.
h Verify the delivery scope based on the delivery note.
File a claim with the responsible Baumüller representative if the delivery is incomplete.
NOTE!
Claim each individual deficiency as soon as it has been detected. Damage claims can
only be validly asserted within the claim registration period.
5.5 Disposal of the packaging
The packaging consists of cardboard, plastic, metal parts, corrugated cardboard and/or wood.
h When disposing of the packaging, comply with the national regulations.

6 MOUNTING
In this chapter we describe the mechanical mounting of the device into a control cabinet.
Mounting consists of the following steps:
1 Prepare mounting (drill holes/cut-out segments)
2 Install device
6.1 Safety notes
NOTE!
Mounting shall only be performed by employees of the manufacturer or by other qual-
ified personnel.
Qualified personnel are persons who – on account of their occupational training, ex-
perience, instruction and knowledge of relevant standards and stipulations, accident
prevention regulations and operating conditions – are authorized by the persons re-
sponsible for the safety of the facilities to perform the respective activities that are
necessary, while at the same time recognizing and preventing any potential risks.
The qualifications necessary for working with the device are, for example:
m Occupational training or instruction in accordance with the standards of safety en-
gineering for the care and use of appropriate safety equipment.

6.1 Safety notes
WARNING!
Danger as a result of faulty mounting!
The mounting requires qualified personnel with adequate experience. Faulty mount-
ing can lead to life-threatening situations or substantial material damage.
Therefore:
m Only allow mounting to be performed by employees of the manufacturer or by oth-
er qualified personnel.
WARNING!
Danger of mechanical impact!
Secure devices against falling down.
Therefore:
m Use appropriate means of transport.
NOTICE!
Danger due to electrostatic discharge.
The connecting terminals of the device are partially at risk due from ESD.
Therefore:
Please heed the respective notes.
CAUTION!
Danger due to sharp edges.
If the device is lifted with unprotected hands during mounting, palms or fingers can
be cut. If the device falls, feet could be injured.
Therefore:
m Ensure that only qualified personnel, who are familiar with the safety notes and as-
sembly instructions, mount this device.
Wear safety gloves.
Wear safety shoes.

Mounting 6
6.2 Preparing for mounting
Based on the planning documents and the drilling pattern, the cutout sections and the positions
of the attachment drill holes can be determined.
NOTICE!
Property damage due to conductive contamination.
Therefore:
m When performing installation work of any kind, it must be ensured that no foreign
material (e.g. drill shavings, copper strands, etc.) gets into the device as a result.
m If possible, the drilling of the holes should be done before mounting the device and
the configuring of the cables should take place outside of the control cabinet. If this
is not possible, the device must be appropriately covered.
Remove this covering again prior to start!
CAUTION!
Eye injury due to flung particles.
Metal particles are flung when making the drill holes and the cutout sections.
Therefore:
Wear protective eye wear!
h Preparing drill holes and cutout sections.

6.2 Preparing for mounting
6.2.1 Drilling patterns
Use the drilling pattern to make the necessary drill holes/cutout sections.
NOTE!
Consider the minimum clearances for cooling when making the drill holes.
All dimensions in millimeters [mm].
Further notes see ZDimensions– on page 23 and ZEnvironmental requirements– on
page 26.
How to determine the required space in the control cabinet, see ZDimensions– on page 23.
Tolerance
specifica-
tions Drill hole dimensioning ±0.2 mm
Relative tolerance of discretionary divisions ±0.1 mm
Figure 6: Drilling pattern

Mounting 6
6.3 Mounting instructions
h Install the units vertically in a switching cabinet. If there are several units, mount them next to
one another.
NOTICE!
It is crucial to comply with the ventilation measures listed below.
Ignoring these measures can lead to the unit overheating.
h Die Belüftung muss von unten nach oben erfolgen.

h Für ungehinderte Luftzufuhr ist zu sorgen.
h Ensure that there is a minimum clearance of at least 100 mm above and below the unit and
ensure that there is enough cooling air that can circulate freely!
h The temperature of the coolant 100 mm below the devices may be up to 45° C. At higher tem-
peratures (up to a maximum of 55° C), reduce the power of the devices by 3 % per degree
Celsius.
h Do not locate any additional sources of heat above or below the devices.
h Avoid degrees of contamination 3 and 4 according to standard DIN EN 61800-5-1, chapter
4.3.6.1.2, (table 6). The devices are suitable for use in enclosed workshop (VDE0558 Part
1a, Sections 5.4.3.2.1 and 5.4.3.2.2).
DANGER!
The discharge time of the device is > 1 min.

6.3 Mounting instructions

7 INSTALLATION
In this chapter we describe the electric installation of the device. The mechanical installation is
described in ZMounting– on page 37.
Before installing assure, that the technical preconditions are fulfilled:
1 Check the requirements to the electrical power supply and check if the existing power supply
is suitable.
2 Check the requirements to the electrical cables and provide the according cables.
3 Check the characteristics of the connections and configure the connections accordingly.
7.1 Safety instructions
NOTE!
Installation shall only be performed by employees of the manufacturer or by other
qualified personnel.
Qualified personnel are persons who – on account of their occupational training, ex-
perience, instruction and knowledge of relevant standards and stipulations, accident
prevention regulations and operating conditions – are authorized by the persons re-
sponsible for the safety of the facilities to perform the respective activities that are
necessary, while at the same time recognizing and preventing any potential risks.
The qualifications necessary for working with the device are, for example:
m Occupational training or instruction, and the authorization to commission, ground
and mark electrical power circuits and devices in accordance with the standards of
the safety engineering.
m Occupational training or instruction, in accordance with the standards of work safe-
ty, for the care and use of appropriate safety equipment.

WARNING!
Danger because of faulty installation and initial commissioning!
Installation and commissioning require qualified personnel with adequate experi-
ence. A installation fault can cause danger situations or large damage of property.
Therefore:
m Only personnel from manufacturer or qualified personnel operate while installation
and initial commissioning
DANGER!
Inevitably, when operating this electrical device, certain parts of it are energized with
hazardous voltage.
Therefore:
m Pay heed to areas on the device that could be dangerous during the electrical in-
stallation.
m Pay heed to areas on the device that could still be electrically energized after op-
eration.
Danger from
residual en-
ergy
DANGER!
discharge time.
Therefore:
the capacitors.

Installation 7
7.2 Voltage test
DANGER!
During the routine test of these devices, a voltage test is performed by Baumüller
Nürnberg GmbH in accordance with EN 61800-5-1, Section 5.2.3.2. It is thus unnec-
essary for the customer to do this.
Therefore:
m Subsequent tests of the devices using high voltages may only be performed by
Baumüller Nürnberg GmbH.
m Disconnect the converter from the system during high-voltage testing!
7.3 Requirements to the supply system
For all important data, see ZRequirements to the energy supply / supply system– from page 25.
Minor deviations from requirements in the power supply can lead to malfunctioning of the de-
vice. If the power supply deviates too much from the requirements, the device can be destroyed.
The devices may only be operated in industrial networks.
The destruction of the device can cause personal injury.
DANGER!
If the requirements for the power supply are not complied, the device can be dam-
aged or destroyed, thereby greatly endangering individuals.
Therefore:
m Prior to installation, ensure that the demands for power supply have been fulfilled.
7.4 Requirements to the connecting cables
h Take into account IEC/EN 60204-1, Chapter 13 when selecting the cable.
h The protective ground cross-section of the cable must be compliant with IEC/EN 60204-1,
Section 5.2, Tab. 1.
h A fixed connection for the protective ground conductor is mandatorily specified for operation
of the device.
h Use copper cable approved for a minimum of 60 °C (drives < 3 x 100 A) or 75 °C (drives ≥ 3
x 100 A), if comply with UL 508C.

7.5 Protection of the device and the cable
7.5 Protection of the device and the cable
Fuses must be installed to protect this device and the cables against overload and possible
damage/destruction through the electrical power supply. For data on the required fuses, see
ZFull range fuses (semiconductor and line protection)– on page 28.
7.6 PE connection and RCD compatibility
Depending on the functional principle, leakage current >3.5 mAAC or >10 mADC can flow
through the protective ground conductor. Consequently, a stationary ground conductor connec-
tion in accordance with EN 61800-5-1 is required.
DANGER!
This product can cause direct and/or alternating current in the protective ground con-
ductor.
The leakage current, due to the functional principle of the device, can lead to prema-
ture triggering of the fault current protective device or generally prevent triggering of
it.
Therefore:
m Wherever a differential current device (RCD) is used for protection in case of direct
or indirect contact, only an RCD of the type B is permitted on the power supply side
of the device.
m Otherwise a different protective measure must be utilized, such as separation from
the surroundings by means of double or enhanced isolation, or separation from the
power supply system by means of an isolating transformer, for example.
7.7 Installation requirements with regard to EMC
NOTE!
The emission of radio frequency interference (RFI) is to a great extent dependent on
the wiring, spatial expansiveness and the arrangement of the components in the sys-
tem. Ensuring electromagnetic compatibility compliance in accordance with legal re-
quirements is therefore only possible on the completely assembled system and is
thus the responsibility of the system manufacturer or proprietor (re Art. 6, Par. 9 of
the EMVG; European EMC law).

Installation 7
HINWEIS!
The important information on EMC-compliant installation can be found in these in-
struction handbook. Additional notes on building a CE-compliant system, that are im-
perative to take heed of, can be found in the Baumüller manual „Mains filter BFN“.
This manual can be obtained from Baumüller Nürnberg GmbH.
m Use Baumüller motor cables and Baumüller components.

m Use a suitable mains filter of Baumüller Nürnberg GmbH
m Mount all components to one single mounting board with well electroconductive surface (e.
g. galvanized steel plate).
m Establish the ground connection converter/ground plane as short as possible (< 30 cm) with
fine-wired cables and a great cross section (> 10 mm2).
m Assure, that the motor cables always consist of one piece.
Do not interrupt the motor cables e. g. by terminals, conductors, fuses a.s.o.
m Run the cables directly on the surface of the grounded mounting board.
(smallest possible effective aerial height).
m Keep a minimum clearance of 30 cm between signal/control and 24V-wires towards electric
power cables at parallel laying.
m Cross cables with different EMC categories (signal cables - supply cables or motor cables)
only in a 90° angle.
m Contact the external cable screens when passing through walls, which separate different
EMC ranges.
m Connect the cable shields of the Mono Power Unit / Power Module-devices plane on both
ends and highly conductive with ground.
m It is recommended to use protection elements against overvoltage in each 24 V control cab-
inet sub-distribution (e.g. Phoenix Contact part no. 2839318 type: PT2-PE/S-24AC-ST) when
using a peripheral 24 V supply (that means the 24 V power supply is not within the device’s
control cabinet).
NOTE
The capacitive coupling of the signals is reduced by factor 5 if a clearance of at least
30 cm is maintained compared with a cable laying directly side by side.
Baumüller has already considered on EMC view that the recommended clearance of
30 cm is not maintained on the supply and the Baumüller devices, therefore this is
uncritical and permitted.

7.8 Operating sequence of installation
7.8 Operating sequence of installation
DANGER!
Electrically live parts are life-threatening.
Therefore:
m Make certain that the parts to be mounted (e.g. power supply cables) and the
mounting areas are de-energized for the entire duration of mounting the device.
h Lay all cables EMC-compatible.

h Connect cables (see ZConnection diagrams– from page 49).
(refer to the permissible torque)
The following steps must be carried out at installation:

1 Connect the motor via the terminals 1U2, 1V2, 1W2, PE. Attend to the in-phase connection
(rotational direction).
(refer to the permissible torque)
2 Connect the device via the power input terminals 1U1, 1V1 and 1W1 to the power choke
output - not necessary for BUS 60.
3 Connect the protective conductor to the terminal PE (a permanent PE connection is required
imperatively).
4 Connect the 24 V supply
(in case you consider UL 508 C: limit the current to 4 A).
5 Connect the controller (see operation manual controller)

Installation 7
7.9 Connection diagrams
7.9.1 Connection diagram BUM 60
Power supply 3x400 V
Main contactor K1
Fuse or
Fan
circuit breaker
Brake
Display
or
1)
When using an external ballast resistor, remove wire bridge between RBint and BA- and connect the external ballast
resistor to X1:2 and X1:4
If UL508C has to be observed: the external ballast resistor must protect itself from overheating
Figure 7: Connection diagram BUM 60

7.9 Connection diagrams
7.9.2 Connection diagram BUS 60
Fan
Brake
Display
ZK+
Power
supply DC link
ZK-
or
Figure 8: Connection diagram BUS 60

Installation 7
7.10 Connection information
Controller Refer to separate operation manual controller
K1 Main contactor with auxiliary contact for controller enable
DANGER!
A controller enable on the controller may not be issued until the DC link capacitors
have been completely charged, i.e. 1 s at the earliest after switching on the main con-
tactor.
F Circuit breaker according to VDE 0100, slow blow fuse, 2...2.3 times the rated current or
motor circuit breaker matched to the power requirements of the drive and to the peak switch
on current.
1U2, Motor connections, cross-section according to VDE 0113/0298.

1V2, Use shielded cables.
1W2, For installation, see ZInstallation requirements with regard to EMC– from page 46.
PE2 Cross-sections: 1,5 mm2 up to 14 A, 2,5 mm2 up to 19 A, 4 mm2 up to 25 A, 6 mm2 above
25 A rated motor current. Observe the assignment to the connections in the terminal box.
1U1, Connection to power supply. Cross-section according to VDE 0113/0298.

1V1, For installation, see ZInstallation requirements with regard to EMC– from page 46.
1W1,
PE1
NOTE
One of the terminals is not connected when single-phase power supply.
RBint Connection of an internal ballast resistor

BA- Connection of a ballast transistor; Connection of an external ballast resistor between ZK+ and
BA-
If UL508C has to be observed:
The external ballast resistor must protect itself from overheating

7.10 Connection information
DANGER!
When using an external ballast resistor, you must remove the wire bridge between
RBint and BA-. Otherwise, the ballast transistor is overloaded and destroyed.
ZK+, ZK- Connections for DC link
BUM 60: Connections for DC link

Discharging the DC Link capacitor takes at least one minute.
If necessary, the DC Link can be rapidly discharged via a resistor.
Connect an external ballast resistor between ZK+ and BA-.

The external ballast resistor must protect itself from overheating.
BUS 60: Connections for DC link power supply
DANGER!
Parallel switching several devices via the DC Link connections is not allowed. This
overloads the starting current limitation device and destroys it.

Installation 7
7.11 Terminal and pin assignments
7.11.1 Power terminals
1U1, 1V1, 1W1, PE (connections: 4 mm2 maximum)
1U1, Device input voltage

1V1,
1W1
NOTE
One of the terminals is not connected when single-phase power supply.
PE Ground switching cabinet
1U2, 1V2, 1W2, PE (connections: 4 mm2 maximum)
1U2, Motor connections

1V2,
1W2
PE Ground connection motor
ZK+, ZK- (connections: 4 mm2 maximum)
BUM 60: Connections for DC link

Discharging the DC Link capacitor takes at least one minute.
If necessary, the DC Link can be rapidly discharged via a resistor.
Connect an external ballast resistor between ZK+ and BA-.
BUS 60: Connections for DC link power supply
RBint, BA-
With internal ballast bridge

With external ballast, refer to ZBlock diagrams– from page 33 and ZConnection diagram
BUM 60– on page 49.
The external ballast resistor must protect itself from overheating.

7.12 Accessories
7.11.2 Pin assignment
NOTE
All control voltages applied externally must comply with the regulations for PELV or
SELV.
Sub-unit terminal X5
BUM 60 - 12 / 24 - 54 - B - ... (required)
Terminal No. Assignment
1 + 24 V / 2 A (PELV) - Anschluss für Netzteilversorgung der Geräte
2 Masse 24 V / 2 A (PELV) - Anschluss für Netzteilversorgung der Geräte
7.12 Accessories
EMC Package can be supplied on request:

f EMC filter
f Screened cables
f Connecting pieces

8OPERATION
Basic
information
WARNING!
Risk of injury due to improper operation!
Improper operation can lead to severe personal injury or material damage.
Therefore:
m Perform all operational steps according to the details of these instruction hand-
book.
m Before beginning any work, ensure that all coverings and protective devices are
installed and are functioning properly.
m The control cabinet in which the device is installed should be protected against
contact with electrically live parts.
Keep all doors of the control cabinet closed during operation.
NOTICE!
Environmental conditions that do not meet the requirements.
Environmental conditions that are non-compliant can lead to property damage.
Therefore:
m Ensure that the environmental conditions are kept compliant during operation (see
ZEnvironmental requirements– on page 26).

8.2 Operation
WARNING!
Risk of injury due to insufficient qualifications!
Inevitably, when operating this electrical device, certain parts of this device are ener-
gized with hazardous voltage. Improper handling can lead to significant personal in-
jury and material damage.
Therefore:
m Only qualified personnel may work on this device!
8.2 Operation
The device is operated using the controller (refer to the description of the controller).
Messages stored in the feed current converter / motor-end inverter can be reset by a reset signal
from the controller.

Operation 8
8.3 Messages and warnings
8.3.1 Monitoring facilities of the feed current converter
For the monitoring facilities to function, the 24-V auxiliary voltage (at X5) must be available.
Ballast overload monitoring

Ballast overload monitoring prevents inadmissibly high loading of the internal brake resistor
(ED < 3 %).
Power supply failure / phase failure monitoring (optional)

Phase failure monitoring detects a single-phase or three-phase failure of the supply voltage and
prevents an internal ready for use.
The phase failure monitoring is not activated by default settings. Note derating while single
phase operation (see ZElectrical data– from page 27).
NOTE
The message can be reset by a RESET on X1 after 2 s after a renewed connecting
of the supply voltage if the 24 V auxiliary voltage or 230 V additional power supply
remains.
For a normal switch-on a simultaneously switch-on of the power supplies on X1 and
X5 is recommended.
8.3.2 Monitoring on motor-end inverter
The following monitoring facilities exist:

f Overcurrent in motor lines
f Earth-fault current
f DC Link overvoltage
f Fault of power transistors (IPM)
f Auxiliary power supply
Overcurrent message
The system monitors the motor current in two motor phases and generates an overcurrent mes-
sage if a phase current is 30 % higher than the allowed peak current.
This message is saved and results in a pulse disable.
The monitoring of 2 phases provides a limited short circuit protection.
The overcurrent message can be reset by a reset signal from the controller.
For display and resetting of the message, refer to the description of the controller.
NOTE
The overcurrent message is intended as protection; the controller ensures limitation
of the allowed peak current of the motor phase currents.

8.3 Messages and warnings
Earth fault monitoring

To detect a motor earth fault the system has a two-phase monitoring of the earth fault current of
the motor-end inverter resp. motor phases. An earth fault current error message is generated if
the fault current exceeds 10 % of the allowed peak current of the power unit. By this two-phase
monitoring the unit is partly earth leakage resistant.
Earth fault monitoring can be reset by a reset signal from the controller.
DC link monitoring
The system monitors the level of the DC Link voltage in the motor-end inverter. A message is
issued if the DC Link voltage reaches a value that is critical for the power unit.
DC Link monitoring can be reset by a reset signal from the controller.
NOTE
The DC Link voltage can rise until switch off if the drive brakes and the ballast power
of the ballast circuit on the DC Link is either too small or no ballast circuit exists.
Monitoring power transistors

The junction region temperature is monitored. The system generates a message if the junction
region temperature exceeds 110 °C.
This message can be reset by a reset signal from the controller.
Monitoring the auxiliary voltage supply

The system monitors the auxiliary voltage supply of the power unit and issues a message if an
undervoltage occurs.
This message can be reset by a reset signal from the controller.
Monitoring the heatsink temperature

The power unit does not have its own temperature monitoring facility, since the temperature of
the heatsink is not a time-critical variable.
On the heatsink, there is a linear temperature sensor whose measured value is passed on to
the controller. This means that the controller carries out temperature monitoring (refer to the de-
scription of the controller).

9 MAINTENANCE
9.1 Safety notes
Basic infor-
mation
DANGER!
Inevitably, when operating this electrical device, certain parts of it are energized with
hazardous voltage.
Therefore:
m Pay heed to areas on the device that could be dangerous during the electrical in-
stallation.
m Pay heed to areas on the device that could still be electrically energized after op-
eration.
WARNING!
Risk of injury due to improperly performed maintenance work!
Improper maintenance can lead to severe personal injury and material damage.
Therefore:
m Before beginning work, make sure that there is enough space for mounting.
m Make sure that the mounting area is kept clean and orderly. Parts and tools that
are loosely stacked or lying around are a potential accident source.

9.2 Environmental conditions
9.2 Environmental conditions
If the prescribed environmental conditions are adhered to, then the device is maintenance-free.
For the prescribed environmental conditions, see ZEnvironmental requirements– auf Seite 26.
The most important prescribed environmental conditions are:
m Dust-free environmental air
m Temperature: Min. 5 °C to max. +55 °C
m Relative humidity: 5% to 85%, no condensation
m Installation altitude: From 1000 m and higher derating
9.3 Inspection intervals - maintenance notes
Preventive maintenance is prescribed to keep the device in an optimum operating condition and
ensure a long service life. It is recommended to have inspections performed regularly by quali-
fied personnel.
Daily Basic check points as to whether discrepancies have occurred during operation:
inspection: m Does the motor work as desired?
m Is the operating environment normal?
m Is the cooling system working normally?
m If an unusual vibration or noise is noticed during operation.
m Does the motor overheat during operation?
Regularly Before checking, switch off the input voltage and wait until the device's capacitors have dis-
scheduled charged.
inspection:
DANGER!
Therefore:
m Switch off voltage before performing work!
m Only qualified personnel may mount, install and maintain the devices.
m Please remove all metallic objects worn, such as watches or rings, for example,
before beginning to work on the device.
m Only insulated tools are permitted.

Maintenance 9
DANGER!
discharge time.
Therefore:
the capacitors.
9.3.1 Periodic maintenance
m Environmental condition
Check points Methods and criteria Inspection intervals
Daily Semi- Annu-
annu- ally
ally
Check environmental temperature, humidity and Visual inspection and measurement of the environmen- O
vibrations. tal conditions, comparison with standard values.
Check whether dust, oil or drops of water appear.
Check whether there are hazardous objects in the Visual inspection O
vicinity.
m Voltage
Daily Semi- Annu-
annu- ally
ally
Check the voltage of the power supply system and Measurement and comparison with standard values. O
the control circuits

9.3 Inspection intervals - maintenance notes
m Mechanical parts
Daily Semi- Annu-
annu- ally
ally
Are there any abnormal noises or vibrations? Visual and audio check O
Are there any loose screws? Tighten the screws. O
Are there any bent or damaged parts? Visual inspection O
Have there been any color changes due to over- Visual inspection O
heating?
Are there any dust or dirt deposits? Visual inspection O
m Power supply
Daily Semi- Annu-
annu- ally
ally
Are there any missing or loose screws? Replace the screws or, respectively, tighten them. O
Is there any deformation, cracking, damage or Visual inspection O
color change on the device as a result of overheat-
ing or aging?
Are there any dust or dirt deposits? Visual inspection O
m Connections and circuitry of the mains power supply

Daily Semi- Annu-
annu- ally
ally
Does the wiring indicate any color or shape Visual inspection O
changes due to overheating?
Is the wiring insulation damaged or is it discol- Visual inspection O
ored?
Is there any damage? Visual inspection O
m Transformer and chokes in the main circuit

Daily Semi- Annu-
annu- ally
ally
Are there any abnormal vibrations or noticeable Visual inspection, audio check and odor check O
odors?

Maintenance 9
m Solenoid switch and relay in the power supply circuit
Daily Semi- Annu-
annu- ally
ally
Are there any loose screws? Visual and audio check Tighten screws, if necessary. O
Do the switches function correctly? Visual inspection O
m Plug connectors in the power supply circuit

Daily Semi- Annu-
annu- ally
ally
Are there any loose screws or connectors? Tighten screws and firmly stick in plug connector. O
Are there any noticeable odors or color Visual inspection and odor check O
changes?
Is there any cracking, damage, deformation or Visual inspection O
corrosion?
Is there any leaking fluid or deformation of the Visual inspection O
capacitors?
m Cooling system fans

Daily Semi- Annu-
annu- ally
ally
Are there any abnormal noises or vibrations? Visual and audio check O
Are there any loose screws? Tighten the screws. O
m Cooling system ventilation duct

Daily Semi- Annu-
annu- ally
ally
Are there any obstructions in the heat sink, air Visual inspection O
supply or air outlet?

9.4 Repairs
9.4 Repairs
In case of device damage, please inform your sales office or:
Baumüller Nürnberg GmbH

Ostendstr. 80 - 90
90482 Nuremberg
Germany
Tel. +49 9 11 54 32 - 0
Fax: +49 9 11 54 32 - 1 30
Mail: [email protected]
Internet: www.baumueller.de

10 SHUTDOWN, STORAGE
In this chapter we describe, how you decommission and store the device.
h Refer to ZSafety– from page 11 and the information in ZTransport and Packaging– from
page 35.
The shutdown of the device may only be carried out by for this qualified personnel.
DANGER!
discharge time.
Therefore:
the capacitors.
m Assure, that all electric connections are current-free and are safe against switch-
on.
m Before working, check at the electrical connections with suitable measuring devic-
es, that the connections are off-circuit.
m Remove the connections not until the safe isolation from supply has been checked.

10.2 Requirements to the executing personnel
10.2 Requirements to the executing personnel
The personnel, who is appointed to setting out of operation, must have the required knowledge
and instructions, which is necessary for an execution according to the rules. Select the person-
nel in such a way, that the safety instructions, which are mounted to the device and its parts as
well as to the connections, are understood and applied to.
10.3 Shutdown
Execute the setting out of operation as follows:

1 put the device off-circuit and assure the device against unintentional restart.
2 check the isolation from supply of all connections (earliest 10 minutes after switching off).
3 demount the connections and protect the connections according to the safety instructions.
4 document the shut down setting.
10.4 Demounting
The demounting assumes a completed, documented setting out of operation.
NOTICE!
Note sharp edges.
In case, while installing, you lift a device with unprotected hands, fingers/palm can be
cut. If the device falls off, your feet can be cut up.
Therefore:
Therefore:
sembly instructions, demount this device.
Wear safety gloves.
fWear safety shoes.
1 secure the device against falling off/out.

2 loosen all mechanical connections.
3 lift the device out of the control cabinet.
4 store the device in a suitable packing.
5 at transportation pay attention to, that the device is not damaged by wrong storage or severe
shocks, also see ZWhat to observe when transporting– on page 35.
In case you want to dispose the device, additional data is available in chapter ZDisposal– from
page 69.

Shutdown, storage 10
10.5 Storage conditions
The device is maintenance-free. If you keep to the environmental conditions during the entire
period of storage, you can assume, that the device will not be damaged. In case the environ-
mental conditions during storage are not kept, you should assume that the device is damaged
after storage.
CAUTION!
Property damage because of incorrect storage conditions
Incorrect storage can damage/destroy the device.
Therefore:
Assure, that the environmental conditions are kept during the entire period of storage:
f Climatic category 1K4
f Temperature range -25 °C to +55 °C
CAUTION!
Recommissioning without forming of the capacitors.
From six months storage period on, the capacitors are destroyed during commission-
ing, if they are not formed beforehand
f Reform the DC link capacitors:
g by supplying the device ready-to-operate for at least one hour with supply volt-
age
g but do not transmit a pulse enable during this time.
f Consider, that it is imperative, to connect the accordingly prescribed line commu-
tating reactor for this forming procedure.Devices, where no line commutating reac-
tor is necessary can directly be supplied with mains voltage.

10.6 Recommissioning
10.6 Recommissioning
Execute commissioning as with a new device, see

ZMounting– from page 37, ZInstallation– from page 43.
CAUTION!
Recommissioning without forming of the capacitors.
From six months storage period on, the capacitors are destroyed during commission-
ing, if they are not formed beforehand
f Reform the DC link capacitors:
g by supplying the device ready-to-operate for at least one hour with supply volt-
age
g but do not transmit a pulse enable during this time.
f Consider, that it is imperative, to connect the accordingly prescribed line commu-
tating reactor for this forming procedure.Devices, where no line commutating reac-
tor is necessary can directly be supplied with mains voltage.

11 DISPOSAL
NOTE
Baumüller products do not belong to the scope of the EU guideline for the disposal of
electrical and electronics devices (WEEE, 2002/96/EG). Therefore, no costs are to
be carried by Baumüller for the canceling and disposal of old devices.
11.1 Safety notes
DANGER!
discharge time.
Therefore:
the capacitors.

11.1 Safety notes
CAUTION!
Danger due to sharp edges.
If the device is lifted with unprotected hands during deinstallation, palms or fingers
can be cut. If the device falls, feet could be injured.
Therefore:
sembly instructions, mount this device.
Wear safety gloves.
Wear safety shoes.
WARNING!
Danger of physical impact!
Secure device against falling down.
Therefore:
m Take suitable measures, such as supports, hoists and assisting personnel, to en-
sure that device cannot fall down.
m Use appropriate means of transport.
NOTICE!
Avoid polluting the environment as a result of improper disposal.
Therefore:
m Only dispose in compliance with the health and safety regulations.
m Take heed of any special local regulations. If you are unable to directly ensure safe
disposal yourself, commission a suitable disposal contractor.
m In the event of a fire, hazardous substances could possibly be generated or re-
leased.
m Do not expose electronic components to high temperatures.
m Beryllium oxide is used as inner insulation, for example for various power semicon-
ductors. The beryllium dust that is generated upon opening is injurious to the
health.
Do not open electronic components.
m Dispose of capacitors, semiconductor modules and electronic scrap as special
waste.

Disposal 11
WARNING!
Danger as a result of faulty deinstallation!
The deinstallation and disposal requires qualified personnel with adequate experi-
ence.
Therefore:
m Only allow deinstallation and disposal to be performed by qualified personnel.
11.2 Disposal facilities/authorities
Ensure that the disposal is handled in compliance with the disposal policies of your company,
as well as with all national regulations of the responsible disposal facilities and authorities. In
case of doubt, consult the bureau of commerce or environmental protection authority responsi-
ble for your company.

11.2 Disposal facilities/authorities

APPENDIX A - ABBREVIATIONS
AC Alternating current
AM Asynchronous motor
a.m.s.l. above mean sea level
BB Ready for use
BUC Baumüller Converter Feed/Feed
Back Unit
BUG Baumüller Converter Basic Feed
Unit
BUM Baumüller Mono Power Unit
BUS Baumüller Power Module
DC Direct current
DIN Deutsches Institut für Normung
e.V.
(German Standardization Authori-
ty)
EMC Electromagnetic compatibility
EN European Standard
HS Main contactor
IPM Intelligent power module
PE Protective earth
PELV Protective extra-low voltage
RS Controller disable
SELV Safe extra-low voltage
SM Synchronous motor
UZK DC link voltage
ZK DC link

A

APPENDIX B - DECLARATION OF
CONFORMITY
B.1 Declaration of conformity

B.1 Declaration of conformity
EG - Declaration of Conformity Doc.-No.: 5.13007.00

Date: 2013-03-12
according to EMC Directive 2004/108/EC and

Low Voltage Directive 2006/95/EC
The Manufacturer: Baumüller Nürnberg GmbH

Ostendstraße 80-90
90482 Nuremberg, Germany
declares, that the products with the
designation: BUS 60X - X -X - 54 - X - XXX
BUM 60X - X -X - 54 - X - XXX
type: Power module BUS 60 / Mono power unit BUM 60
manufactured since: 2013-03-12
are developed, designed and manufactured in accordance with the EMC Directive 2004/108/EC and the Low Voltage Di-
rective 2006/95/EC.
Applied harmonized standards:
Standard Title
DIN EN 62061:2010-05 Safety of Machinery - Functional safety of safety-related electrical, electronic and programmable
electronic control systems
DIN EN 61800-5-1:2008-04 Variable-speed electrical power drive
Part 5-1: Safety requirements - Electrical, thermal and energy
DIN EN 61800-5-2:2008-04 Variable-speed electrical power drive
Part 5-2: Safety requirements - Functional
DIN EN 61800-3:2005-07 Variable-speed electrical power drive
Part 3: EMC requirements and specific test methods
The products must be installed correctly and all notes and safety notes of the referring instruction handbook must be com-
plied with, to guarantee the compliance of the guidelines.
Nuremberg / 2013-03-12
City / Date
Subject to change of this declaration of EC conformity without notice. Actual valid edition on request.

Table of Figures
Table of Figures
Signs .......................................................................................................................................... 20
Type plate .................................................................................................................................. 21
Dimensions ................................................................................................................................ 23
Block Diagram BUM 60 - XX/XX - 54 - X - XXX......................................................................... 33
Block diagram BUS 60 - XX/XX - 54 - X - XXX .......................................................................... 34
Drilling pattern ............................................................................................................................ 40
Connection diagram BUM 60 ..................................................................................................... 49
Connection diagram BUS 60...................................................................................................... 50

Index
Index
A motor end 32
Accessories 54
Accidents 18 J
Additional sources of heat 41 Junction region temperature 58
B K
Ballast circuit 32 Key to symbols 8
Block diagram 34
L
C Limitation of liability 9
Cable screens 47
Caution 8 M
Customer service 10 Maintenance 59
Maintenance, periodic 61
D Monitoring
Danger 8 auxiliary voltage 58
Danger situation 18 DC link 58
Declaration of conformity 75 earth fault 58
Degrees of contamination 41 feed current converter 57
Demounting 66 heatsink temperature 58
Design 31 overcurrent message 57
Disposal 10 phase failure 57
power transistors 58
E Monitoring facilities
Edges, sharp 38, 66 motor-end inverter 57
Electrical current, dangers of 16 requirements 57
EMC package 54 Mounting 37
Energy supply / requirements 25 Moving 17
Moving components, danger from 17
F
Feed current converter 32 N
Fire fighting 17 Note 8
Functions 32 Notice 8
Fuses 28
O
G Operating personnel 14
Guarantee provisions 10 Operating requirements 24
Operation 55
H
Hard hat 15 P
Hazards, special 16 Packaging, disposal of 36
PE connection 46
I Personnel, qualified 14
Inductance 25 Personnel, training 14
Inductance, power supply 25 Protection class 13
inspection 60 Protective equipment 15
Inspection intervals 60 Protective eye wear 15
Installation Protective gloves 15
preconditions 43 Protective work clothing 15
Installation space 37
Installation, operating sequence 48 R
Inverter Recommissioning 68

Index
Repairs 64
Residual energy, danger from 16, 44
S
Safety 11
Safety equipment 18
Safety shoes 15
Shutdown 65, 66
Signs 19
Signs and labels 19
Spare parts 10
Starting current load relief 32
Storage 65
Storage conditions 67
Sub-unit terminal 54
Supply system 25
T
Technical data 23
Temperature of coolant 41
Temperature range 26
Terminals 48
Transport 35
Transport inspection 36
Type plate 21
U
Unpacking 36
Usage, compliant with the intended purpose
12
V
Voltage test 45
W
Warning 8
Warning notes 8
Weight 24

Overview of Revisions
Overview of Revisions
Version Status Changes
5.01032.05 18.03.2013 New layout, Chapter overview of revisions added,

note for break time after switch-off added,
note added: monitoring of 2 lines ensures only limited short circuit protec-
tion

Notes:

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Instruction Handbook: English

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Instruction handbook

Mono Power Unit /

E 5.01032.05 Read the Instruction handbook before starting any work!

© Baumüller Nürnberg GmbH

4 Design and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Instruction handbook BUM 60 / BUS 60 3

5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4 Instruction handbook BUM 60 / BUS 60

Appendix B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Instruction handbook BUM 60 / BUS 60 5

6 Instruction handbook BUM 60 / BUS 60

Instruction handbook BUM 60 / BUS 60 7

1.2 Key to symbols

8 Instruction handbook BUM 60 / BUS 60

1.4 Copyright protection

The instruction handbook must be treated confidentially. It is to be used exclusively by person-

1.5 Other applicable documents

Instruction handbook BUM 60 / BUS 60 9

1.6 Spare parts

1.8 Guarantee provisions

1.9 Customer service

Our customer service is available to provide you with technical information.

1.10 Terms used

10 Instruction handbook BUM 60 / BUS 60

2.1 Contents of the instruction handbook

2.2 Changes and modifications to the device

Instruction handbook BUM 60 / BUS 60 11

2.3 Usage for the intended purpose

12 Instruction handbook BUM 60 / BUS 60

2.5 Protective devices

Instruction handbook BUM 60 / BUS 60 13

2.6 Training of the personnel

14 Instruction handbook BUM 60 / BUS 60

Protective work clothing

Protective eye wear

Instruction handbook BUM 60 / BUS 60 15

2.8 Special hazards

16 Instruction handbook BUM 60 / BUS 60

2.9 Fire fighting

ABC powder / CO2

Instruction handbook BUM 60 / BUS 60 17

2.10 Safety equipment

2.11 Conduct in case of danger or accidents

Preventive m Always be prepared for accidents or fire!

18 Instruction handbook BUM 60 / BUS 60

Instruction handbook BUM 60 / BUS 60 19

20 Instruction handbook BUM 60 / BUS 60

Figure 2: Type plate

Instruction handbook BUM 60 / BUS 60 21

22 Instruction handbook BUM 60 / BUS 60

Instruction handbook BUM 60 / BUS 60 23

Weight without controller cassette ca. 7 kg

3.3 Operating requirements

3.3.1 System types

Supported system types

24 Instruction handbook BUM 60 / BUS 60

Supply system Industrienetz mit hart- oder niederimpedant