Bum 60 S: Single Power Unit

Single Power Unit
BUM 60 S
Manual
E 5.05001.01
Title Manual
Product Single Power Unit BUM 60 S
Version 5.05001.01
Status 2005-01-26
Copyright These operating instructions may be copied by the owner in any

quantity but only for internal use. For other purposes these op-
erating instructions and extracts thereof must not be copied or
reproduced.
Use and disclosure of information contained in these operating
instructions are not permitted.
Designations and company marks contained in these operating
instructions may be brand names, the use of which by third par-
ties for their own purposes may violate the rights of the holders.
Obligatory These operating instructions are part of the equipment/ma-
chine. These operating instructions must be available to the op-
erator at all times and must be in a legible condition. If the
equipment/machine is sold or moved to a different location
these operating instructions must be passed on by the owner to-
gether 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, cor-
responding sets of operating instructions of a previous version
are automatically invalidated. 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.
Baumüller Nürnberg GmbH reserves the right, in developing its
products further, to change the technical specifications and the
handling of the products concerned without prior notice.
No liability can be accepted concerning the correctness of the
operating instructions unless otherwise specified in the General
Conditions of Sale and Delivery.
Manufacturer Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
D-90482 Nürnberg
Germany
Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30
www.baumueller.de
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.2 Block diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Qualified personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Specified application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Voltage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Packing and Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Mounting note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 EMC instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Connection plan BUM 60 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4 Connection instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Connector- and terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.1 Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.2 Connector assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Messages and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.1 Monitoring of infeed converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.2 Monitoring motor-sided inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 Maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix B - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
B.1 Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
B.2 Mechanical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
B.3 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
B.4 Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Manual BUM 60 S 3
Document No.: 5.05001.01 of 60
Table of contents
Appendix C - Declaration of Conformity / by Manufacturer /

UL - Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
C.1 What is an EU directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
C.2 What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
C.3 Definition of the term Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
C.4 Definition of the term Declaration by Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
C.5 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
C.6 Declaration by manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
C.7 UL-certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4 Manual BUM 60 S
of 60 Document No.: 5.05001.01 Baumüller Nürnberg GmbH
1
1 INTRODUCTION
1.1 General information
The single power unit BUM 60 S is suited for the use in the medium range of performance.
The V-controller cards are provided for the control. All V-controllers can be used with one printed
circuit board chart.
NOTE
Because all controller types are equipped with modules, a separate description with the ac-
cording characteristics and technical data can be obtained.
The single power unit BUM 60 S consists of the mains-sided supply converter and of the motor-
sided inverter.
Manual BUM 60 S 5
1.1.1 Functional description
The total unit BUM 60 S consists of the supply converter, the motor-sided inverter and of the
controller module. The different controller modules are not described here, but in separate man-
uals.
f Supply converter
The supply converter at the BUM 60 S is an uncontrolled B6 rectifier with a inrush-current lim-
iting and a chopper circuit.
f Inrush-current limiting
Due to the DC link capacity a direct switch-on of the device to the mains without using a lim-
iting switch would cause inadmissibly high current surges. In order to avoid these current
surges the inrush-current is limited by a resistor.
f Chopper circuit
In certain operating states the connected motor feeds back energy to the converter. This en-
ergy is saved in the DC-link and leads to an increase of the DC-link voltage. In order to avoid
an overvoltage shutdown threshold, the fed back energy is converted into heat from a certain
DC-link voltage in the internal or external chopper resistor.
f Motor-sided inverter
The motor-sided inverter consists of the IGBT-power unit and the associated sensors. On the
one side the sensors provide measuring signals for the control and on the other hand allows
the self-protection of power electronics.
The control of the inverter is executed by the accordingly used controller.
6 Manual BUM 60 S
Introduction 1
1.1.2 Block diagram
Figure 1: Block diagram BUM 60 S
Manual BUM 60 S 7
8 Manual BUM 60 S
2
2 SAFETY INSTRUCTIONS
Preliminary notes
During operation in the converter and in the motor discharging currents always occur against
ground and can result in a premature response to a connected ELCB.
In case of a fault to frame or a ground fault a direct component in the ground leakage can occur,
which complicates or avoids the enable of a higher-level ELCB.
The connection of power unit to the mains only with the use of the ELCB is forbidden (EN 50178/
VDE 0160/4.98, paragraph 5.2.11 and 5.3.2.1)
The protection against touching of the units is achieved by the mounting of the converters into
conventional control cabinets, which, regarding the protection type comply with the minimum
requirements acc. to EN 50178/VDE 01604.98, paragraph 5.2.4.
Essential for personal protection are the safety precautions and safety instructions acc. to DIN/
VDE.
In case there are missing protective ground connections at the unit or at the motor it must be
reckoned on personal injury and/or considerable property damage.
General notes
This manual contains the required information for the specified use of the described products.
This manual is intended for technically qualified personnel that has been specially trained and
is completely familiar with all warnings and maintenance measures.
The devices are made according to the state-of-the-art technology and are fail-safe. It can be
put into operation and function without problems if you ensure that the information in the manual
is complied with.
WARNING
The following can occur, if you disregard this warning instruction:
f considerable damage to property f serious personal injury f death
When operating with this electrical unit, inevitably certain parts of this unit are under danger-
ous voltage.
Make sure, that only qualified personnel, who is familiar with the safety- as well as with mount-
ing-, operating- and maintenance instructions, works on this unit.
Manual BUM 60 S 9
2.1 Qualified personnel
Safety notes
On the one hand the notes serve as your own security and on the other hand as a security
against damage of the described products or of the connected devices.
The definitions, which are used, have the following meaning in the terms of the manual and of
the notes on the products:
DANGER
The following will occur, if you disregard this safety information:
WARNING
NOTE
This note is a particularly important information.
2.1 Qualified personnel
In terms of notes corresponding to security in this manual or to the products itself, qualified per-
sonnel are persons, who are familiar with the installation, mounting, commissioning and opera-
tion of the product and who possess qualifications, which accord with their work :
f Education or instruction or to have the authorization to put into operation, ground and label
circuits and devices according to the standards of safety engineering.
f Training or instruction due to the standards of the safety engineering in maintenance and use
of appropriate safety equipment.
10 Manual BUM 60 S
Safety instructions 2
2.2 Specified application
WARNING
The unit/system may only be used in the cases, which are described in the manual and may
only be used with those devices and components of other manufacturers, which were recom-
mended or permitted by Baumüller Nürnberg GmbH.
Arbitrary reconstructions and changes at the device are not permitted because of safety rea-
sons.
The operator must immediately notify changes, which affect the security of the device/system.
2.3 Voltage check
At the routine test of these units a voltage check is executed acc. to EN 50178/VDE 0160/4.98,
paragraph 9.4.5 by Baumüller Nürnberg GmbH.
Subsequent checks of unit with high voltages must be executed only by Baumüller Nürnberg
GmbH.
WARNING
If you want to check the complete control cabinet installation with high voltage, you must sep-
arate all cable connections from the Baumüller units before checking.
Manual BUM 60 S 11
2.3 Voltage check
12 Manual BUM 60 S
3
3 PACKING AND TRANSPORTATION
The devices are packed in the manufacturing company according to the order.
h Avoid strong transportation vibrations and severe hits, e.g. when setting down.
After unpacking and the check for completeness and the sound condition mounting can follow.
The packing is made of cardboard, corrugated cardboard and/or wood. They can be disposed
according to the local disposal regulations.
h A transport damage is immediately to be notified.
DANGER
If there is a transport damage at the unit, this may not be connected to the supply voltage with-
out a correct voltage test.
Manual BUM 60 S 13
14 Manual BUM 60 S
4
4 MOUNTING
WARNING
The user carries the responsibility for the mounting of the described device according to the
Safety instructions (e. g. EN, DIN, VDE) and other important national or local regulations,
which concern conductor dimensioning and protection, grounding, disconnectors, overvolt-
age protection a.s.o.
Cooling air intake and outtake must be unrestrictedly possible. There must be enough free
space above and below the device, otherwise the device can overheat.
Manual BUM 60 S 15
4.1 Dimensions
4.1 Dimensions
16 Manual BUM 60 S
Mounting 4
4.2 Mounting note
WARNING
Incorrect lifting can lead to personal lifting or damage to property. Lift the unit only with suit-
able equipment and/or with the help of qualified personnel.
h The devices must be installed vertical into the control cabinet. If you have several devices
these must be built in side by side.
WARNING
The following cooling measures must be observed unconditionally.
At non-observance the device can overheat.
h Ventilation must take place bottom-up.

h Unrestricted air supply must be provided.
h Free space above and below the devices must be at least 50 mm
.Make sure, that there is enough cooling air and that there is air circulation!
h Cooling air temperature 50 mm below the device up to 40 °C. At higher temperatures (up to
55 °C) the power of the devices is reduced by 3% per °C.
h Do not group additional heat sources above and below the devices.
h Degree of pollution 3 and 4 according to EN 50178:4.98 paragraph 5.2.15.2 must be avoided.
The devices can be mounted in isolated operating areas. (VDE 0558 part 1a, paragraph
5.4.3.2.1 and 5.4.3.2.2).
DANGER
Discharging time of components under voltage is > 1 min.
Manual BUM 60 S 17
4.2 Mounting note
18 Manual BUM 60 S
5
5INSTALLATION
5.1 Safety notes
WARNING
This unit is under dangerous voltage and contains dangerous rotating machine parts (fan).
The user accounts for the mounting of the power units, the motor, the mains choke as well as
the other devices according to the safety instructions (e. g. DIN, VDE) and all the other rele-
vant national or local regulations concerning PCB dimensioning and protection, grounding,
disconnectors, overvoltage protection a.s.o.
Essential for personal protection are the safety precautions and safety instructions acc. to
DIN/VDE. If, at the device there are missing protective connections, at the commutating choke
or at the motor it must be reckoned with personal damage, because there can be dangerous
voltages on the surface.
During operation in the power unit and in the motor there are discharge currents to ground,
which are discharged via the specified protective connection and can result in a release of a
connected ELCB.
In case of a fault to frame or a ground fault a direct component in the ground leakage can oc-
cur, which complicates or avoids the enable of a higher-level ELCB.
The protective conductor connection must be executed to DIN EN 60204/VDE 0113 part 1/
1997; paragraph 8.2.2 with consideration to EN 50178 / VDE 0160/ 4.98, paragraphs 5.3.2.1
and 8.3.4.4.
If there is an error then the drive is changed to zero-current, after that the motor coasts down
non-braked. This must especially be considered at travel- and lift drives.
Before activating the drive the function of all higher-levelled safety devices must be checked
thoroughly, in order to avoid personal danger.
Manual BUM 60 S 19
5.1 Safety notes
WARNING
f severe injury f death
The danger is: electricity. Parts, which are under tension are perilous.
Assure, that the parts, which must be mounted (e. g. mains cables) and the mounting range
are off-circuit during the entire mounting of the device.
WARNING
Incorrect behavior of the drive
During the initial operation an incorrect or uncontrolled movement of the powered machine
elements can occur. Therefore you must approach with reasonable caution.
Protection against accidental contact according to §4 para. 4 VBG 4
Protection against direct contact, cover all measures against danger, which consults from the
contact to active parts of electric equipment.
Control cabinets must have emergency stops, where all voltages. which can cause hazards,
can be switched off. This does not include equipment, where a new hazard occurs, when it is
switched off. The tripping device for the emergency stops must be placed in such a manner,
that it can be reached quickly, if there is an hazardous situation. In case there are obviously
dangerous operations to be executed, then the presence of a further person is necessary.
The operator must assure that only authorized persons are working at the machine.
The operator is bound to immediately notify, if there are changes on the machine, which could
have influence on the security.
Before the demounting of safety equipment during commissioning, repair and maintenance
the machine is to be shutdown according to the regulations. Immediately after completion of
commissioning-, repair- and maintenance working, the remounting of the safety equipment
must be done and the safety equipment must be checked.
20 Manual BUM 60 S
Installation 5
5.2 EMC instructions
General information about converter

In Baumüller Nürnberg GmbH converters IGBTs are used. Due to the quick switch of the IGBTs
the power loss in the converter is minimized. Therewith the size of the power units was reduced.
However the quick switching of the IGBTs can lead to electromagnetic interferences, which can
influence other parts.
Interferences can be caused by:
f Capacitive leakage current. The cause is the high voltage gradients at the switching of bipolar
transistors and IGBTs.
f High currents and current gradients in the motor cables. The bonded interference energy in
the magnetic field reaches frequencies of a few hertz up to about 30 MHz. Due to the high
voltage gradients additionally electromagnetic fields with frequencies up to 600 MHz occur.
f High clock-pulse rates and quick logic switchings (electromagnetic field of 16 MHz to 1 GHz).
f Reaction on system and harmonics. The cause are commutation procedures and not sinuso-
idal mains loadings especially at line-commutated converters (100Hz... 20 kHz).
EMC regulation (EMVG)

This converter accords to § 6 para. 9 of the EMVG dated September 18, 1998:
„Devices, systems and parts in terms of paragraph 3, which exclusively are manufactured and
are determined as subcontracting parts or spare parts for the subsequent processing by com-
petent companies or persons in the field of electromagnetic compatibility, must not fulfill the pro-
tection requirements as well as the requirements of § 4 para. No. 1 to 3 and 5 comply with.“
Thereby it is allowed for, that in order to comply with the EMC it is decisive, how the single parts
and components are mounted in the control cabinet.
Measures for EMC-assurance

In order to minimize electromagnetic interferences, certain preconditions must be complied with
at cabling, grounding, screening and at mounting of filters. The notes of the following page will
help you, to configure the installation according to the latest EMC knowledge.
Cabling
f For suppression of the interfering radiation outside the converter you basically must screen
all connected cables. If the control cabinet has a sufficiently high degree of screening atten-
uation (see limit values of the radio interference emission according to EMVG for your instal-
lation) and if the EMC compatibility in the interior space is guaranteed (you may assume that,
if all configuration notes have been adhered to), the control cables also may be mounted un-
screened.
Manual BUM 60 S 21
Also refer to the information under ZScreening– from page 25.
Figure 2: Cabling power unit
f The compliance with the permissible limit values of the interference resistance and the inter-
ference emission can only be assumed, if you exclusively use Baumüller motor cables and -
components.
f The maximum length of motor cable is limited. The maximum length of the motor cable is de-
pendent on the cross section of cable (e. g. 100 m at 1.5 mm2, 30 m at 35mm 2).
f The screened motor cable between converter and motor must be made of one piece. Do not
interrupt the cable e. g. with terminals contactors, fuses and so on.
22 Manual BUM 60 S
Installation 5
f The smallest possible effective aerial height is to be reached, if you install the cable directly
on the surface of grounded chassis.
Figure 3: Cable laying - aerial height
f All cables should basically be laid as near as possible to the conductors of the chassis ground
system, in order to reduce the loop area which is effective for magnetic decoupling.
Figure 4: Cable laying - loop area
f At parallel laying of signal or control cables compared with power cables you must comply
with a minimum clearance of 20 cm between the conductors.
f Cross cables of different EMC categories only in a 90 °angle.
f At symmetrical signal transmission (e.g. differential amplifier inputs for the speed setpoint)
you must link the conductors of each core pair together, and then link the core pairs one with
another.
f The ground connection converter/ground plane must be as short as possible (<30cm) and
must be fine-wired. Use great cross-sections (>10 mm2).
f Connect the bus connection on the load side of the filter with low-impedance to the mounting
mounting board. Ideal is a zinc-plated sheet metal angle or a HF-grounding band.
f Interferences as contactors, transformers, chokes and noise sensitive modules as μPs, bus
systems and so on should have at least 20 cm clearance to the converter and its cabling.
f Avoid reserve loops at cables, which are too long.
f Ground the reserve cable always on both ends (additional screening effects, avoid capacitive
coupled, dangerous contact voltages).
Manual BUM 60 S 23
f Don’t switch mains filters parallel.

f Don’t connect mains filters of the same type of construction in series - the attenuation char-
acteristics will not be approved.
f Suppress each drive individually from interferences. In case all drives must be suppressed
from interferences, do not interrupt the screens between converter and the line filter. This
means, that the screened cables are not to be interrupted by fuses, contactors or others.
Grounding
f In order to minimize the influence of interferences with higher frequencies, which arise due to
the operation of the converter, for purposes of EMC the classical star-connected grounding
is inadequately. Better results is achieved with a reference surface, which is large-formatted
connected with the grounding potential of the devices (i.e. metallic bright mounting board and
housing parts).
f To avoid ground loops, position all ground conductors and screens as close as possible to
ground.
f If you have the possibility to ground the controller reference potential of the converter, exe-
cute this connection with a great cross section and with a short cable (< 30 cm).
f Remove insulation layers such as painting, adhesives a. s. o. from the ground connections.
If necessary use a serrated lock washer (DIN 6798) in order to penetrate the surface and
therewith reach a durable, highly conductive contact. In order to prevent corrosion of ground
connections you select suitable metal combinations (consider electro-chemical insulation rat-
ing). Conductive electrolytes are kept away from the connection with a protection film (e. g.
grease).
f Always connect the screens on both ends plane and highly conductive with ground. Only like
this magnetic or high-frequency interference fields are able to be attenuated in its actions. At
problems with ground loops (e. g. double grounding of setpoint conductor screen) the receiv-
er side should be put on conductive and the sender side capacitive.
f Contact the external cable screens when passing through walls, which separate different
EMC ranges.
Cables, which are led through walls of screened cabinets without special precautions (e. g.
filtering), can influence the screening effects of this cabinet. Therewith connect the cable
screens also at the exiting point with a well conductive screening.
The distance of the last screen contact point to the cabinet exit must be as short as possible.
Figure 5: Cable laying - cabinet outlet
24 Manual BUM 60 S
Installation 5
Screening
f Screening is effective against magnetic fields if the screen is connected to ground on both
ends.
With electrical fields a screening effect is already existent if the screen is connected to ground
on one side.
Fields with high frequencies (dependent of cable length) always are electromagnetic fields.
Thereby it doesn’t matter if it is an electric or magnetic field. At these fields the screening always
has to be done on both sides.
Figure 6: Cable laying - to apply screen
With both-sided applying of the screen on ground you reach that the cable doesn’t leave the
screening system housing.
f The both-sided grounding of cable screenings nearly excludes an influence due to ground
loops (potential differences on the ground system). These are very rare, if the notes from the
sections ZCabling– from page 21 and ZGrounding– from page 24 are regarded.
The HF-connection of a screen with ground can also occur capacitive. This avoids low-frequent
errors due to ground loops.
Screening cables which pass different EMC ranges, may not be opened at the terminals, be-
cause the screening attenuation otherwise decreases highly. They must lead to the next module
without interruptions.
The screen connection must occur with large surface area and with low impedance. Cable tails
with a length of only 3 cm (1 cm wire = 10 nH) reduce the screening effect at errors in the MHz
range up to 30dB!
NOTE
The braided screen must have a coverage of at least 85%.
The following cables possess an especially high interference potential:
f Motor cable
f Cable to external chopper resistors
f Cable between mains filter and converter (if length > 30 cm)
Manual BUM 60 S 25
Figure 7: Proposal for screening connection
26 Manual BUM 60 S
Installation 5
Cable diameter ∅ (mm) Part no.
2 x 2 - 6 mm 226752
3 - 8 mm 226741
4 - 13.5 mm 226745
10 - 20 mm 226749
Greater cross sections on

request
Figure 8: Screening terminals for grounding
Manual BUM 60 S 27
5.3 Connection plan BUM 60 S
5.3 Connection plan BUM 60 S
1)
At external chopper resistor remove bridge between RBint and BA- and connect external chopper resistor between
X1:2 and X1:4.
In case UL508C is considered: The external chopper resistor must protect itself against overheating.
28 Manual BUM 60 S
Installation 5
5.4 Connection instructions
Controller See separate controller description

module
K1 Main contactor, with auxiliary contact for controller release
DANGER
Controller release at the controller must be made after the complete loading of DC-link capac-
itors, this is, at the earliest, 1 s after switching on the main contactor
F Cable protection according to VDE 0100, fuse delayed, 2...2,3-time rated current or motor
protector, matched to the power requirement of the drive and of the starting peak current.
1U2, Motor connections. Cross section according to VDE 0113/0298.

1V2, Use screened cables.
Laying of the cables see ZEMC instructions– from page 21.
S
1W2,
Cross sections: 1.5 mm 2 to 14 A, 2.5 mm2 to 19 A, 4 mm2 to 25 A, 6 mm2 via 25 A motor
rated current. Consider the connections in the terminal box.
1U1, Connection to mains. Cross section according to VDE 0113/0298.

1V1, Laying of the cables see ZEMC instructions– from page 21.
S
1W1,
NOTE
At one-phase supply one connection not required.
RBint Connection internal chopper resistor

Ba- Connection chopper transistor; Connection external chopper resistor between DC+ and BA-.
In case UL508C is considered: The external chopper resistor must protect itself against over-
heating.
Manual BUM 60 S 29
5.4 Connection instructions
DANGER
If you are using an external chopper resistor the bridge between RBint and BA- must be re-
moved. Otherwise the chopper transistor will be overloaded and destroyed.
DC+, DC- Connection of DC-link voltage

Connections of DC-link voltage. Discharge of the DC link capacitors lasts at least 1 minute.
Quick discharge of the DC-link via resistor, if necessary. Connection of an external chopper
resistor between DC+ and BA-.
heating.
DANGER
A parallel switching of several devices via the DC-link connection is not permitted. Due to this
the inrush-current limiting is overloaded and destroyed.
30 Manual BUM 60 S
Installation 5
5.5 Connector- and terminal assignment
5.5.1 Power connections
1U1, 1V1, 1W1, S (connections: maximum 4 mm2)
1U1, Input voltage of device

1V1,
1W1
NOTE
At one-phase supply one connection not required.
S Control cabinet-ground
1U2, 1V2, 1W2, S (connections: maximum 4 mm2)
1U2, Motor connections

1V2,
S
1W2
Ground connection motor
DC+, DC- (connections: maximum 4 mm2)
Connection of DC-link voltage

Connections of DC-link voltage. Discharge of the DC link capacitors lasts at least 1 minute.
Quick discharge of the DC-link via resistor, if necessary. Connection of an external chopper
resistor between DC+ and BA-.
RBint, Ba-
At internal chopper resistor bridge

At external chopper resistor see ZBlock diagram– from page 7 and ZConnection plan BUM
60 S– on page 28.
heating.
Manual BUM 60 S 31
5.6 Accessories
5.5.2 Connector assignment
NOTE
Assure that all externally-applied control voltages meet the regulations for
PELV or SELV.
Plug-in terminal X5
Connection No. Assignment
1 + 24 V / 2 A (PELV) - Connection for power supply of the devices
2 Reference potential 24 V / 2 A (PELV) - Connection for power supply of

the devices
5.6 Accessories
EMC-stack can be delivered on request:

f EMC-filter
f Screened cables
f Connection parts
32 Manual BUM 60 S
6
6COMMISSIONING
6.1 Safety notes
WARNING
Not meeting with safety- and warning notes can lead to death, severe personal injury or dam-
ages to property.
The user is in charge of the mounting of the power units, the motor, the mains filter as well as
of the other devices according to safety regulations (e. g. DIN, VDE) and the other relevant
national and local regulations, which regard conductor dimensioning and grounding, discon-
necting switches, overcurrent protection a.s.o.
Essential for personal protection are the safety precautions and safety instructions acc. to
DIN/VDE. If the protective conductor is not connected to the existing protective conductor
connections of device and motor, it must be anticipated that personal injury occurs, be-
cause there can be dangerous voltages on the surface.
The power connections of power unit are non-isolated!
Even if the main contactor is falling the parts of the power unit are under dangerous voltages.
During operation in the power unit and in the motor there are discharge currents to ground,
which are discharged via the specified protective connection and can result in a release of a
connected ELCB.
In case of a fault to frame or a ground fault a direct component in the ground leakage can oc-
cur, which complicates or avoids the enable of a higher-level ELCB.
The protective ground connection must be executed according to DIN EN 60204 / VDE 0113
part 1 / 1997; paragraph 8.2.2 considering EN 50178 / VDE 0160/ 4.98, paragraphs 5.3.2.1
and 8.3.4.4.
Incorrect behavior of the drive
During the initial operation an incorrect or uncontrolled movement of the powered machine
elements can occur. Therefore you must approach with reasonable caution.
Manual BUM 60 S 33
6.1 Safety notes
WARNING
Before activating the drive the function of all higher-levelled safety devices must be checked
thoroughly, in order to avoid personal danger.
Special caution is necessary at direct or indirect contact of drive shaft (of hand). This is only
permitted at standstill of what and off-circuit power unit. If there are uncovered machine parts,
these must be covered at operation (shafts, fans, or similar).
Contact protection according to §4 para. 4 VBG 4
Protection against direct contact contains all measures against dangers, which occur at the
contact of voltage-controlled parts of electric equipment.
The voltage-controlled parts must be protected against direct contact by insulation, type of
construction, assignment or fixed-mounted equipment. This concerns the usual covers, guard
and procedures, which guarantee, that persons cannot touch the parts, which are under volt-
age.
Control cabinets must have emergency stops, where all voltages. which can cause hazards,
can be switched off. This does not include equipment, where a new hazard occurs, when it is
switched off. The release of the emergency stop must be attached, so that, if there is danger,
it can be reached quickly. In case there are obviously dangerous operations to be executed,
then the presence of a further person is necessary.
The operator must assure that only authorized persons are working at the machine.
Subsequent checks of unit with high voltages must be made only by Baumüller Nürnberg Gm-
bH. If you want to check complete control cabinet installation with high voltage, you must sep-
arate all cable connections from the Baumüller units before checking.
If there is an error then the drive is changed to zero-current, after that the motor coasts down
non-braked. This must especially be considered at travel- and lift drives.
The operator is bound to immediately notify, if there are changes on the machine, which could
have influence on the security.
Before demounting safety equipment for commissioning, repair or maintenance set the ma-
chine in exact accordance with the instructions out of operation. Directly after completion of
commissioning-, repair- and maintenance works, the re-mounting of the safety equipment
must be made and this must be checked.
This is not a complete listing of all required measures for the safe operation of the power unit.
Should you require further information or if there are specifically problems, contact Baumüller
Nürnberg GmbH or a sales branch office.
Please regard to the warning notes in chapter ZSafety instructions– from page 9.
Units with electrostatic endangered components or modules are tagged at a visible position
with this label.
34 Manual BUM 60 S
Commissioning 6
NOTE
Before touching the modules the operator must discharge himself electrostatic, in order pro-
tect electronic parts of high voltages, which can occur at electrostatic charge. This can hap-
pen, by touching a conductive and grounded part directly before.
6.2 Operation
The operation of the device is made via the controller (see according controller description).
The saving of messages in the infeed converter/motor-sided inverter can reset with a reset sig-
nal from the controller.
6.3 Messages and warnings
6.3.1 Monitoring of infeed converter
For the monitoring functioning there must be a 24V-auxiliary supply.
Chopper resistor monitoring

The chopper resistor monitoring avoids an inadmissible overload of the internal chopper resistor
(ED < 3 %).
Mains-/phase failure monitoring (option)

The phase failure monitoring recognizes a one- and a three-phase failure of the supply voltage
and avoids an internal ready-to-operate.
NOTE
If there is a 24V-auxiliary voltage at X5 the message can only be reset 2 s after a re-switch in
of the supply voltage at X1 via RESET. For switch on under normal operating conditions a
simultaneously switching of the supply voltages at X1 and X5 is recommended.
Manual BUM 60 S 35
6.3.2 Monitoring motor-sided inverter
The following monitoring is present:

f Overcurrent in the motor cables
f Ground fault current
f DC-link overvoltage
f Power transistors
f Overtemperature
Overcurrent message
The motor current in the motor phases is monitored and an exceeding of a phase current by
30 % of the permissible peak current generates an overcurrent message. This message is
saved and causes a pulse inhibit.
The overcurrent message can be reset by the reset of the controller.
Display and reset of message see description of the controller.
NOTE
The overcurrent message is regarded as a protection, the limit of the permissible peak current
of the motor phase current is guaranteed by the control.
Ground current monitoring

The ground current of the motor-sided inverter and therewith of the motor phases is monitored
at two phases, in order to recognize a motor grounding. A ground current error message is gen-
erated, if the error current exceeds 10 % of the permissible peak current of the power unit. By
the monitoring of two phases the device is conditionally ground fault protected.
The ground current monitoring can be reset by a reset of the controller.
DC-link monitoring
The level of the DC-link voltage is monitored in the inverter. If the DC-link voltage reaches a val-
ue, which is critical for the power unit, a message is generated.
The DC-link monitoring can be reset by a reset of the controller.
NOTE
The DC-link voltage can increase until switch-off takes place, if the drive brakes and if there
is no or too little chopper circuit with a too little chopper power at the DC-link circuit.
Monitoring of power transistors

The junction temperature is monitored. A message is generated, if a junction temperature of
110 °C is exceeded.
This message can be reset by a reset of the controller.
36 Manual BUM 60 S
Commissioning 6
Monitoring of the heatsink temperature
The power unit has no own temperature monitoring, because the temperature of the heatsink is
no time-critical factor.
On the heatsink there is a linear temperature sensor, whose measured value is transmitted to
the controller. The controller therewith takes over the temperature monitoring (see description
of the controller).
6.3.3 Error messages
NOTE
When using the BUM 60 S together with the V-controller then only the error messages below
are valid.
The accordant error messages in the documentation for the V-controller are invalid!
Function module supply (error identification 01xx)
Error Error text Meaning Error reaction Troubleshooting

identifi-
cation
0110hex Check mains voltage at the

The signal „Ready-to-operate“ supply unit.
of the supply unit is missing Reset error memory in the
Possible cause: Immediate pulse supply unit (see manual supply
Error Supply unit Error 0203hex unit)
inhibit
Error 0204hex Other trouble shooting: see
Error 0207hex error 0203hex, 0204hex as well
as 0207hex
Manual BUM 60 S 37
Function module power unit (error identification 02xx)

identifi-
cation
0201hex The DC-link voltage U DC has
Immediate pulse
U DC link overvoltage exceeded the value of 810 V± Check chopper resistor
inhibit
1%
0202hex Check the setting of the cur-
At least one of the three phase rent controller.
currents of the power unit has
and
exceeded the max. current.
Check the motor cables and
Overcurrent/leakage or Immediate pulse
the motor for ground fault.
current In the power unit leakage cur- inhibit
and
rent was determined, which
Check the three phases of the
has exceeded a certain
motor cables on currents with
amount.
the same amplitude.
0203hex „Pulse release“ is set.
Phase error/under- The DC-link voltage U DC has Immediate pulse
Check mains voltage.
voltage fallen below a value of about inhibit
190V repeatedly with load.
0204hex Check the setting of the cur-
Too much energy was dissi-
Chopper resistor Immediate pulse rent controller. Is the bridge
pated in the chopper resistor
overload inhibit between BA- and RBint miss-
at braking.
ing?
0205hex The error can be accepted
Error reaction only then, if the temperature
Overtemperature Die power unit temperature
settable via under P118 has fallen below
power unit has exceeded 85°C.
P189 the displayed power unit tem-
perature of 85°C.
0206hex nonexistent - - -
0207hex Check the fan
Overtemperature Cabinet bottom of power mod- Immediate pulse Check the controller
power module ule has exceeded about 110°C inhibit (controller has not sensed
temperature correctly)
0208hex
0209hex
020A hex
nonexistent - - -
020Bhex
020C hex
020D hex
020Ehex Read power unit version at the

The control device does not
Power unit identifica- Immediate pulse type plate and compare it with
recognize the read identifica-
tion unknown inhibit the list under P117. Error can-
tion
not be cleared.
020Fhex Saved power unit type and
read power unit type do not
correspond, because e. g. no Check parameter setting and,
Incorrect power unit Immediate pulse
data set was saved or if necessary, change it. Save
type inhibit
because the control device data set and clear errors.
was plugged into another
power unit.
38 Manual BUM 60 S
Commissioning 6
identifi-
cation
0210hex The ready-to-operate signal of

the power unit is missing,
Immediate pulse
Error power unit although there are no other
inhibit
error messages from the
power unit.
0D01hex The power unit temperature
has fallen below the threshold
Via P090 error Temperature sensing faulty,
Short-circuit tempera- of -40°C. Normally this error
reaction can be no trouble shooting is possi-
ture sensor occurs, if the temperature
set. ble.
sensing is short-circuited dur-
ing operation.
Manual BUM 60 S 39
40 Manual BUM 60 S
7
7 MAINTENANCE
WARNING
The noncompliance with the safety- and warning notes can cause to death, severe bodily in-
jury or to damages to property.
Maintenance- and repair works must be made only in an off-circuit status of the device.
Begin with works at the unit, if you have assured, that there is neither potential nor voltage
(residual load) present.
In order to commission or repair, set the machine in exact accordance with the instructions
out of operation before beginning with the demounting of safety devices. Directly after com-
pletion of commissioning-, repair- and maintenance works the mounting of the safety devices
must be made.
After each intervention in the drive (it does not matter if in the motor, actual value sensing or
in the converter), the user of the machine must approve the machine and document this chro-
nological in the machine protocol (maintenance notebook or similar). At non-compliance legal
consequences will be initiated against the user.
7.1 Maintenance notes
The devices, which are supplied are maintenance-free.
Prohibition of arbitrarily reconstructions

Arbitrarily reconstructions or changes of any kind at the drive are prohibited due to safety rea-
sons.
Manual BUM 60 S 41
7.2 Storage conditions
7.2 Storage conditions
If you keep to the environmental conditions during the entire period of storage, you can assume,
that the device will not be damaged.
WARNING
From a six month storage period on, the capacitors are destroyed during commissioning, if
they are not reformed beforehand.
Reform the capacitors by supplying the device ready-to-operate for at least 48 hours with sup-
ply voltage, but do not transmit a pulse enable.
7.3 Recommissioning
Execute commissioning as with a new device
WARNING
From a six month storage period on, the capacitors are destroyed during
commissioning, if they are not reformed beforehand.
Reform the capacitors by supplying the device ready-to-operate for at least
48 hours with supply voltage, but do not transmit a pulse enable.
42 Manual BUM 60 S
Maintenance 7
7.4 Disposal
The devices mainly exist of the following components and materials:
Components Material
Spacers, cabinet of current transformer and of the device fan Plastics

etc.
Printed circuit board, on which the entire drive and control Base material: Epoxy resin fiber glass reinforce-
technology is stored. ment, copper-lined two-sided and plated through;
Electric parts as capacitors, resistors, relays, semi-
conductors, etc.
The electric parts can contain dangerous substances.

At appropriate use of the different parts there are no dangers for persons and environment.
Dangerous materials may result or may be set free from a fire.
The electronic parts should not be opened, as the inner insulation, e. g. with different power
semiconductors beryllium-oxide is used.
When opened, the beryllium dust is dangerous to your health.
The disposal of the devices or modules must be made according to the statutory regulations of
the according country and of the regional and local ordinances respectively or must be appro-
priately recycled.
Manual BUM 60 S 43
7.4 Disposal
44 Manual BUM 60 S
A
APPENDIX A - ABBREVIATIONS
AC Alternating current TBA Overtemperature of ballast resis-
tor
AM Asynchronous motor
TKK Overtemperature of heat sink
a.m.s.l. above mean sea level
TMO Overtemperature of motor
BB Ready for use
UVS Supply voltage too low
BUC Baumüller Converter Feed/Feed
Back Unit UZK DC link voltage
BUG Baumüller Converter Basic Feed ZK DC link
Unit
BUM Baumüller Single 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
FBS BEDAS missing
FLG Fault in position encoder signal
FPH Missing phase
FTO Fault in tachometer generator sig-
nal
HS Main contactor
MC Main contactor
IPM Intelligent power module
IZK Overcurrent in intermediate circuit
NMX Maximum RPM exceeded
PE Protective earth
PELV Protective extra-low voltage
RS Controller disable
SELV Safe extra-low voltage
SGR Current limit reached
SM Synchronous motor
Manual BUM 60 S 45
A
46 Manual BUM 60 S
B
APPENDIX B - TECHNICAL DATA
B.1 Required environmental conditions
Operational ambient temperature range TB 1) 0 ... 40 °C

(with derating (3 % / °C) to 55 °C)
Cooling air temperature range TK 0 ... 40 °C
(with derating (3 % / °C) to 55 °C)
Reducing of nominal current output (TK = 45...55°C) 3 % / °C
Max. mounting height at load rating 2) Absolute altitude
Relative humidity 15 % ... 85 % not moisture condensated
Storage temperature range -30 °C ... +70 °C
1)
The environmental temperature is determined as follows:
Several measuring points, which cover the entire
drawn in range, determine according to the adjoining
drawing spaced at intervals of 10 cm.
Measure temperature at these measuring points.
The greatest value is the ambient temperature
2)
Load values subject to the site altitude at site altitude > 1000 m
Manual BUM 60 S 47
B.2 Mechanical data
B.2 Mechanical data
Dimensions (W x H x D) 74 x 345 x 217 mm

Weight without controller cartridge 3.75 kg
B.3 Electrical data
BUM 60 S - 04/08
1)
Supply voltage 3 x 400 - 480 VAC 50 - 60 Hz, ± 10 %
9)
Semiconductor protecting fuses (external) 16 A
Type of protection IP 00
Rated DC-link voltage 2) 540 VDC
DC link capacitor 110 µF
Switch on: Ready-to-operate after ≥ 1.5 s
Supply switch-on rate 7) unlimited
10) 11)
Output voltage 3 x 0 VAC ... 95 % of supply voltage
Output power 3) 11) 2.5 kVA
Output rated current 4) 5) 11) 4 Aeff
Output peak current 4) 5) 6) 11) 8 Aeff
Low-voltage supply +24 VDC ± 10 % (max. 55 W)
Chopper resistor R B
Peak power chopper resistor 3 kW / 1 sec.
Continuous power 30 W
External chopper resistor 8) min. 75 Ω
max. turn on time / 1.5 s / 1 : 33
-ratio for chopper resistor operation
Power loss at rated operation
Without low-voltage supply, without chopper resistor 50 W
Permitted transistor pulse frequency 8 kHz
WARNING
At a one-phase connection, none of the two conductors may have ground potential!
1)
One-phase connection possible. Voltage deviation of phase to phase may be +/- 3.0 % at the maximum
2)
All rated values refer to a supply voltage of 400 V;
At a one-phase connection the rated DC-link voltage is reduced by 35 %
3)
At a one-phase connection derating of 66 %.
4)
At a one-phase connection derating of 50 %.
5)
Current details according to controller type
Digital controller: RMS at sine commutation
48 Manual BUM 60 S
Technical data B
6)
For max. 200 ms without preloading at E-controller
For max. 1 s without preloading at V-controller
The load cycle must be measured, so that the resulting RMS of the output current does not exceed the rated current.
7)
A minimum interval time of 2 min. must be adhered to after switch-off.
8)
In case of consideration to UL508C: The external chopper resistor must protect itself against overheating.
9)
Use fuses, which in the operating point have a total operating I2t value (i2t) of maximum 510 A2s.
In case of consideration to UL508C: Use the fuses 32A/1000V: 3NE4 101 of Siemens (part No. 101 940 Baumüller). The appropriate
clamps can be ordered under the part No. 101 960 at Baumüller. You may also use UL-suitable fuses from the table below.
In the table listed below we have further UL-suited fuses but there are also not UL-suited fuses listed. Consider that there are different
types of fuses and that accordant fuse bottom sections must have to be used. Not every fuse listed below fits in the fuse bottom section,
which is available from Baumüller!
Limiting fuses (semiconductor- and cable protection)

Bussmann 00 16A/690V: 170M2692 20A/690V: 170M2693 25A/690V: 170M2694 32A/690V: 170M2695
40A/690V: 170M2696
Gould 0 40A/690V: A0-69E40 50A/1250V: A0-125E50 D1
D8
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
10) The output voltage is a pulsed d.c. voltage. The operating range refers to the effective value of the fundamental wave.
11)
Effective value at an environmental temperature of 40 °C.
12) Between
45° C and 55° C the output current must be reduced. The rated output current is calculated with the following formula:
environmental temperature – 45°C

I A = I A ( 45°C ) ⋅ ⎛ 1 – ------------------------------------------------------------------------------------------------ ⋅ 0, 03⎞
⎝ °C ⎠
Example: Output rated current = 30A, ambient temperature = 47° C:
47°C – 45°C
I A = 30A ⋅ ⎛ 1 – ⎛ ---------------------------------- ⋅ 0, 03⎞ ⎞ = 30A ⋅ 0, 94
⎝ ⎝ °C ⎠⎠
Therewith the output rated current must be reduced: 28.2 A
Manual BUM 60 S 49
B
B.4 Type key
50 Manual BUM 60 S
C
APPENDIX C - DECLARATION OF
CONFORMITY / BY MANUFACTURER /
UL - CERTIFICATION
In this section we provide general information about EU directives, the CE symbol and the Dec-
laration of Conformity/by Manufacturer.
C.1 What is an EU directive?
EU directives specify requirements. The directives are written by the relevant bodies within the
EU and are implemented by all the member countries of the EU in national law. In this way the
EU directives guarantee free trade within the EU.
An EU directive only contains essential minimum requirements. You will find detailed require-
ments in standards, to which references are made in the directive.
C.2 What the CE symbol indicates
a) The CE marking symbolizes conformity to all the obligations incumbent on manufacturers for
the product by virtue of the Community directives providing for its affixing.
…
b) The CE marking affixed to industrial products symbolizes the fact that the natural or legal per-
son having affixed or been responsible for the affixing of the said marking has verified that the
product conforms to all the Community total harmonization provisions which apply to it and has
been the subject of the appropriate conformity evaluation procedures.
…
Council Decision 93/465/EEC, Annex I B. a) + c)
We affix the CE mark to the equipment and to the documentation as soon as we have estab-
lished that we have satisfied the requirements of the relevant directives.
All converters and control systems supplied by the Baumüller Nürnberg GmbH satisfy the re-
quirements of 73/23/EEC (Low Voltage Directive).
As all converters and control systems comply with the requirements of the harmonized stan-
dards EN50178, EN 60204-1, EN 60529 and HD625.1 S1, the protection targets of 73/23/EWG
are reached.
Manual BUM 60 S 51
C.3 Definition of the term Declaration of Conformity
With specified application of this Baumüller equipment in your machinery, you can act on the
assumption that the equipment satisfies the requirements of 98/37/EG (machinery directive).
Therefore the equipment is developed and constructed in such a way, that the requirements of
the harmonized standard EN 60204-1 can be met by the electrical installation.
Compliance with 89/336/EEC (EMC Directive) depends on how the equipment is installed.
Since you are performing installation yourself, it is you who are responsible for complying with
89/336/EEC.
A declaration of conformity on the EMC directive therefore cannot be issued.
We will provide you with support in the form of EMC information. You will find this information in
the operating manual and in “filters for main applications”. When you have complied with all the
requirements we impose in this documentation, you can assume that the drive satisfies the re-
quirements of the EMC Directive.
The limit values and requirements for variable-speed electrical drives are determined in the har-
monized product standard EN61800-3. If you are erecting an installation, for which a declaration
of conformity on the EMC directive must be generated, it may be necessary to specify several
harmonized standards, which you have used for the compliance of the protection targets of the
directive. The harmonized product standard EN 61800-3 has to be used with electrical drives.
To enable you to market your machine within the EU, you must be in possession of the following:
m Conformity mark (CE mark)
m Declaration(s) of Conformity regarding the directive(s) relevant to the machine
C.3 Definition of the term Declaration of Conformity
A Declaration of Conformity as defined by this documentation is a declaration that the electrical

equipment brought into circulation conforms to all the relevant fundamental safety and health
requirements.
By issuing the Declaration of Conformity in this section the Baumüller Nürnberg GmbH declares
that the equipment conforms to the relevant fundamental safety and health requirements result-
ing from the directives and standards which are listed in the Declaration of Conformity.
C.4 Definition of the term Declaration by Manufacturer
A Declaration by Manufacturer as defined by this documentation is a declaration that the ma-

chine/safety component brought into circulation conforms to all the relevant fundamental safety
and health requirements.
By issuing the Declaration of Conformity in this section the Baumüller Nürnberg GmbH declares
that the equipment conforms to the relevant fundamental safety and health requirements result-
ing from the directives and standards which are listed in the Declaration of Conformity .
The Baumüller equipment is integrated into a machine. For health and safety, of the users for
example, it is important for the entire machine to conform to all the relevant fundamental safety
and health requirements. For this reason the Baumüller Nürnberg GmbH draws attention in the
Declaration by Manufacturer to the fact that it is prohibited to put the machine as a whole into
operation before it has been declared that the machine conforms to the provisions of the Ma-
chinery Directive.
52 Manual BUM 60 S
Declaration of Conformity / by Manufacturer / UL - Certification C
C.5 Declaration of conformity
EG-Konformitätserklärung
Declaration of conformity
gemäß EG-Richtlinie 72/23/EG (Niederspannung) vom 19.02.1973

geändert durch: 93/68/EWG vom 22.07.1993
in accordance with EC directive 72/23/EG (low voltage) dated 19.02.1973

changed by: 93/68/EWG dated 22.07.1993
Einzel-Leistungs-Einheit (Mono Power Unit)BUM 60 S - XX/XX - 54 - X - XXX

Das obige Gerät wurde entwickelt und konstruiert sowie anschließend gefertigt in Übereinstim-
mung mit o.g. EG-Richtlinie und u.g. Normen in alleiniger Verantwortung von:
the unit specified above was developed and constructed as well as manufactured in accordance
with the above mentioned directive and the standards mentioned below under liability of:
Baumüller Nürnberg GmbH, Ostendstr. 80 - 90, 90482 Nürnberg, Germany
Berücksichtigte Normen - standards complied with:

Norm / standard
EN 50178 Ausrüstung von Starkstromanlagen mit elektrischen Betriebsmitteln
Electronic equipment for use in power installations
EN 60204-1 Sicherheit von Maschinen - Elektrische Ausrüstung von Maschinen
Safety of machinery - Electrical equipment of machines
EN 60529 Schutzarten durch Gehäuse (IP Code)
Degrees of protection provided by enclosures (IP Code)
HD 625.1 51 Isolationskoordination für elektrische Betriebsmittel in Niederspannungsanlagen
Insulation coordination for equipment within low-voltage systems
Nürnberg, 28.01.2005
Andreas Baumüller ppa. Dr. Peter Heidrich

Geschäftsführer Entwicklungsleiter
Head Division Head of development
Manual BUM 60 S 53
C.6 Declaration by manufacturer
C.6 Declaration by manufacturer
EG-Herstellererklärung
Declaration by manufacturer
gemäß EG-Richtlinie 98/37/EG (Maschinen) vom 22.06.1998

geändert durch: 98/79/EG vom 27.10.1998
in accordance with EC directive 98/37/EG (machinery) dated 22.06.1998

changed by: 98/79/EC dated 27.10.1998
Einzel-Leistungs-Einheit (Mono Power Unit)BUM 60 S - XX/XX - 54 - X - XXX

Das obige Bauteil wurde entwickelt und konstruiert sowie anschließend gefertigt in Übereinstim-
mung mit o.g. EG-Richtlinie und u.g. Normen in alleiniger Verantwortung von:
The part specified above was developed and constructed as well as manufactured in accord-
ance with the above mentioned directive and the standards mentioned below under liability of:
Baumüller Nürnberg GmbH, Ostendstr. 80 - 90, D- 90482 Nürnberg
Berücksichtigte Normen - standards complied with:

Norm / standard
EN 60204-1 Sicherheit von Maschinen - Elektrische Ausrüstung von Maschinen
Safety of machinery - Electrical equipment of machines
Die Inbetriebnahme der Maschine, in die dieses Bauteil eingebaut wird, ist untersagt bis die
Konformität der Maschine mit der obengenannte Richtlinie erklärt ist.
The machinery into which this part is to be incorporated must not be put into service until the
machinery has been declared in conformity with the provisions of the directive mentioned above.
Nürnberg, 28.01.2005
Andreas Baumüller ppa. Dr. Peter Heidrich

Geschäftsführer Entwicklungsleiter
Head Division Head of development
54 Manual BUM 60 S
Declaration of Conformity / by Manufacturer / UL - Certification C
C.7 UL-certification
UL is a mark of conformity, which is assigned from Underwriters Laboratories Inc.

(www.ul.com), an American company. The UL-certification is not statutory regulated, but takes
place voluntarily.
In order to be allowed to mark equipments and components with the UL-mark of confomity, tests
must have to be done, which are attended and documentated by an UL-inspector. Only if all nec-
essary tests have been passed and regular product monitoring at the production process of the
equipment or the components has been passed without objections, the UL-mark of conformity
may be attached to the equipment under test.
Line filters of the company Baumüller Nürnberg GmbH are checked in accordance of the UL-
standard UL 508C (UL-Standard for Safety for Power Conversion Equipment) and are recorded
under the category control number NMMS. The product- and test description is recorded under
file-no. E179860.
Only if all necessary tests have been completely carried out the c-mark may be attached to the
equipments or components. If single tests have not already taken place at the manufacturer´s,
but are carried out not until at the user´s, then only the u-mark may be attached.
With products of the Baumüller Nürnberg GmbH all tests are already completed at the UL-cer-
tification process, so that they may be marked with the c-mark.
In case with the UL-certification process also standards of the CSA (Canadian Standard Asso-
ciation) are considered, then instead of the c- or u-mark the cc or U -mark may be at-
tached to the product.
With products of the company Baumüller Nürnberg GmbH the CSA-standard Norm C 22.2 was
considered, that´s why they are marked with the cc-mark.
If products of Baumüller Nürnberg GmbH are mounted into an UL-certified installation, then cer-
tain application-, mounting- and installation notices must be considered, which are upon the
functioning of the device. We have marked these notes in the manual with „UL 508C ...“. Only if
you follow these notes and apply to them you may go by it, that the installation has been mount-
ed UL-conform.
Manual BUM 60 S 55
C.7 UL-certification
56 Manual BUM 60 S
Index
Numerics M
73/23/EWG 51 Maintenance notes 41
Monitoring
A chopper resistor 35
Accessories 32 DC-link 36
ground current 36
B heatsink temperature 37
Block diagram 7 infeed converter 35
motor-sided inverter 36
C phase failure 35
Cable screens 24 power failure 35
Cabling 21 power transistors 36
Cases of operation precondition 35
provided 11 Motor-sided inverter 6
Checks with high voltages 11
Chopper circuit 6 O
Coolant temperature 17 Operation 35
Overcurrent message 36
D
Declaration by Manufacturer 51 P
Declaration of Conformity 51 Packing 13
Degree of pollution 17 Plug-in terminal 32
E Q
EMC instructions 21 Qualified personnel 9
EMC regulation (EMVG) 21
EMC-stack 32 R
Recommissioning 42
F Required environmental conditions 47
Functional description 6
Fuses 49 S
Screening 25
G Supply converter 6
Grounding 24
T
H Transport damage 13
Heat sources Transportation 13
additional 17 Type key 50
I U
Inrush-current limiting 6 UL-certification 55
J
Junction temperature 36
L
Low Voltage Directive 51
Manual BUM 60 S 57
58 Manual BUM 60 S
Table of figures
Block diagram BUM 60 S ............................................................................................................. 7
Cabling power unit ..................................................................................................................... 22
Cable laying - aerial height......................................................................................................... 23
Cable laying - loop area ............................................................................................................. 23
Cable laying - cabinet outlet ....................................................................................................... 24
Cable laying - to apply screen .................................................................................................... 25
Proposal for screening connection ............................................................................................. 26
Screening terminals for grounding ............................................................................................. 27
Manual BUM 60 S 59
Document No.: 5.05001.01 von 60
Table of figures
60 Manual BUM 60 S
Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg T: +49(0)911-5432-0 F: +49(0)911-5432-130 www.baumueller.de
All information given in this manual is customer information, subject to change without notice. We reserve the right to futher develop and actualize
our products continuously using 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 information in hand.
No liability can be accepted concerning the correctness of the information.

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Single Power Unit

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Appendix C - Declaration of Conformity / by Manufacturer /

1.1.1 Functional description

Figure 1: Block diagram BUM 60 S

2.1 Qualified personnel

2.3 Voltage check

h Ventilation must take place bottom-up.

General information about converter

EMC regulation (EMVG)

Measures for EMC-assurance

Also refer to the information under ZScreening– from page 25.

Figure 2: Cabling power unit

Figure 3: Cable laying - aerial height

Figure 4: Cable laying - loop area

f Don’t switch mains filters parallel.

Figure 5: Cable laying - cabinet outlet

Figure 6: Cable laying - to apply screen

Figure 7: Proposal for screening connection

Greater cross sections on

Figure 8: Screening terminals for grounding

5.3 Connection plan BUM 60 S

Controller See separate controller description

K1 Main contactor, with auxiliary contact for controller release

1U2, Motor connections. Cross section according to VDE 0113/0298.

1U1, Connection to mains. Cross section according to VDE 0113/0298.

RBint Connection internal chopper resistor

DC+, DC- Connection of DC-link voltage

5.5.1 Power connections

1U1, 1V1, 1W1, S (connections: maximum 4 mm2)

1U1, Input voltage of device

1U2, 1V2, 1W2, S (connections: maximum 4 mm2)

1U2, Motor connections

DC+, DC- (connections: maximum 4 mm2)

Connection of DC-link voltage

At internal chopper resistor bridge

5.5.2 Connector assignment

Connection No. Assignment

1 + 24 V / 2 A (PELV) - Connection for power supply of the devices

2 Reference potential 24 V / 2 A (PELV) - Connection for power supply of

EMC-stack can be delivered on request:

6.3 Messages and warnings

6.3.1 Monitoring of infeed converter

For the monitoring functioning there must be a 24V-auxiliary supply.

Chopper resistor monitoring

Mains-/phase failure monitoring (option)

6.3.2 Monitoring motor-sided inverter

The following monitoring is present:

Ground current monitoring

Monitoring of power transistors

6.3.3 Error messages

Function module supply (error identification 01xx)

Error Error text Meaning Error reaction Troubleshooting

0110hex Check mains voltage at the

Function module power unit (error identification 02xx)

Error Error text Meaning Error reaction Troubleshooting

020Ehex Read power unit version at the

0210hex The ready-to-operate signal of

7.1 Maintenance notes