10 pluggable screw terminals - BMR Gmbh

10 pluggable screw terminals - BMR Gmbh

10 pluggable screw terminals - BMR Gmbh


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<strong>BMR</strong> GmbH 2009<br />

MANUAL<br />

Picture shows version SSE, for further available models, see point 3, page 8.

SFU 0303<br />

2<br />

Congratulation<br />

for purchasing a <strong>BMR</strong>-GmbH product.<br />

We thank you for the decision for<br />

choosing a <strong>BMR</strong>-GmbH device<br />

and wish you much success.<br />

Please read<br />

this manual carefully<br />

before the first use<br />

Version 18.Feb.2009

Contents:<br />

1. Introduction 4<br />

2. Description and Features 6<br />

3. Specifications of Device 8<br />

4. Block Diagram 9<br />

5. Technical Data <strong>10</strong><br />

6. Safety and Caution Instructions 11<br />

7. View of Front Panel 12<br />

8. Connections, Plugs and Pin Assignments 13<br />

8.1 Digital and Analog Inputs X2 14<br />

8.2 Digital and Analog Outputs X3 15<br />

8.3 Spindle Interface X416<br />

8.4 Mains Connection, Spindle Connection with Plug Connectors 17<br />

8.5 View of Strip Terminal 17<br />

8.6 RS232, RS485 18<br />

8.7 USB Connection 18<br />

9. Description of Function, Setup, Operation 19<br />

9.1 Starting the Converter 20<br />

9.2 Status Information of LED Display 21<br />

9.3 LCD Operating Panel 22<br />

9.4 Adjustment of Rotation Speed 25<br />

9.5 Safety Functions 26<br />

9.6 Safe Pulse Inhibitor according to EN 954-1 K3 27<br />

<strong>10</strong>. Profibus Connection 27<br />

11. Parametrisation, Configuration with Windows Software 28<br />

12. Automatic Calibration of Spindles and Adjustment 29<br />

13. Examples of Connections 31<br />

13.1 Logic and Safety Circuit 31<br />

13.2 Mains and Spindle Connection 32<br />

14. EMC 33<br />

15. Troubleshooting 34<br />

16. Mechanics, Views, Dimensions 37<br />

17. EC Declaration of Conformity 38<br />

18. General Hints 39<br />

19. Warranty 40<br />

20. Accessories 41<br />


SFU 0303<br />

1. Introduction<br />

Due to its construction, the rotation speed of a 3-phase AC motor is directly dependent on<br />

the frequency of the connected network and on the number of poles. In the case of a network<br />

frequency of 50 Hz and a 2-pole motor, the nominal rotation speed is 50 r/s * 60 = 3000 rpm.<br />

In the case of DC motors (brushless DC), the rotation speed is dependent on the voltage<br />

applied.<br />

AC-Spindles offer a variety of advantages in the industrial area, such as brushless operation,<br />

no wear and tear, favourable capacity/weight ratio, high rotation speed, and much more.<br />

Accordingly, they can be used in a variety of areas, such as in milling and grinding spindles<br />

or in drilling machines.<br />

The advantages of SFU0303 compared to similar frequency converters:<br />

4<br />

Safe pulse inhibitor, authorized according to current regulations of EN 954-1 category 3<br />

In an industrial network an output of up to 5kVA<br />

High efficiency because of symmetrical PWM<br />

Real time vector control for operation without sensor<br />

Maximal torque even with a very low rotation speed<br />

Highest acceleration times can be achieved for low process times, e.g. 25.000 rpm/sec for<br />

a 2.2 KW motor (e.g. for robot applications in process technology)<br />

PAM control possible through regulated intermediate circuit (optional)<br />

Very low rotation speed (<strong>10</strong> rpm) possible e.g. for the start of tool change positions<br />

Lowest possible power input through real time power control system<br />

Optimal integration into existent programmable controllers through open I/0 configuration<br />

Interface to profibus, RS485, RS232, USB<br />

Datalogger (optional) integrated through PC software. Recording of any length of all<br />

relevant parameters in the converter possible. Ideal for the setup of the processing step

Autotuning function -Automatic learning of the motor’s characteristic curves<br />

Test run with graphical evaluation of the motor currents/voltages<br />

Up to 16 different characteristics of spindles can be stored<br />

Very user-friendly debugging interface for setup control<br />

Start/stop interface for cyclic permanent tests or remote control<br />

Operating panel detachable and with extension cable to be used as remote control<br />

Planned for the industrial use when drilling, grinding, milling. Swarf-proof housing<br />

construction prevents the intrusion of impurity into the control electronics<br />

Very compact form of housing allows the unproblematic installation into the<br />

control cabinet<br />

19” housing version for 3HE standard racks<br />

Custom housings on request<br />

User-friendly plug-in system for power and control connections<br />

Wide range of mains voltage 115 V – 230 V<br />

Plug connectors with <strong>screw</strong> elements<br />

Automatic decelaration of the spindle after emergency stop or mains failure<br />

Illuminated amber plain text display<br />

Rotary encoder without mechanical catch for rotation speed control and menu control<br />

Very user friendly operating menu in plain text<br />

Temperature controlled fan<br />

Different models<br />

USB connection<br />

Fully functional even without operating panel<br />

Direct RS232 connection with adapter cable<br />


SFU 0303<br />

2. Description and Features<br />

Operation of AC and DC motors<br />

The high frequency converter SFU-0303 allows for rotation frequencies in AC motors of up<br />

to 500,000 rpm in a 2-pole motor and in DC motors of up to 60,000 rpm.<br />

High output power (3.6 kV with 230 V / 2 kVA with 115 V) in a compact design.<br />

The core of SFU-0303 is a digital signal processor (DSP) which produces all output parameters<br />

and collects signals.<br />

All parameters like power, voltage and frequency are collected in real time and are regulated<br />

by the implemented vector control depending on the load.<br />

High-precision sinusoidal output signals with a low distortion factor and low deformation<br />

allow for optimal rotation qualities in AC motors of all operating conditions.<br />

Allows the highest efficiency of motors with low and with high frequencies.<br />

High operating safety: All operating conditions like acceleration, operation with nominal<br />

rotation speed, braking are controlled and critical conditions are intercepted. This includes<br />

also the controlled braking of the motor / spindle in the case of a power failure or of an<br />

emergency OFF.<br />

Integrated braking resistance (optional). If no breaking resistance is integrated, the braking<br />

times can extend to idleness.<br />

Transparency: The user is always informed on the current status of the converter and the<br />

spindle / motor in the plain text on a 3-line <strong>pluggable</strong> display on the front panel.<br />

Control: The converter can be controlled and parameterised manually with a <strong>pluggable</strong> front<br />

operating unit if the need arises.<br />


Individual adjustment to the current application and the connected spindle. Up to 16<br />

different characteristic lines of the spindle can be produced individually and be stored in the<br />

converter, or existing lines can be modified and adjusted to the application.<br />

A variety of control and communication options: There are 3 connections for the<br />

communication with peripheral devices:<br />

PC, PLC (programmable logic controller), CNC (computer numeric control).<br />

Easy and flexible integration into existing equipments through free configuration of I/O<br />

signals for control and configuration:<br />

Control inputs: 2 analogue, 6 digital<br />

Control outputs: 2 analogue, 6 digital (relays)<br />

Galvanic separation of all interfaces from each other and from the mains / motor potential<br />

Short circuit test<br />

Easy configuration and control with the help of an optional PC Windows software<br />

Automatic calibration of the spindle's characteristic curve<br />


SFU 0303<br />

3. Specifications of Device<br />

Basic system SFU 0303<br />

marking of different versions:<br />

Examples:<br />

8<br />

Brake Resistor / Chopper: 0= without; 1= 220R; 2= <strong>10</strong>R;<br />

Adjustable Intermediate Circuit: 0= without; 1= with<br />

Operating Panel: 0= without; 1= with<br />

Housing: SSE = cabinet mounting; 19“ = rack mounting<br />

T = desktop casing; S= special model<br />

SFU 0303 SSE112 SSE with operating panel and adjustable intermediate circuit, <strong>10</strong>R brake resistor<br />

SFU 0303 SSE<strong>10</strong>2 SSE with operating panel and no adjustable intermediate circuit, <strong>10</strong>R brake resistor<br />

SFU 0303 SSE<strong>10</strong>0 SSE with operating panel and no adjustable intermediate circuit, no brake resistor<br />

SFU 0303 SSE000 SSE without operating panel and no adjustable intermediate circuit, no brake resistor

4. Block Diagram<br />


SFU 0303<br />

5. Technical Data<br />

Mains connection 115V, 60Hz, 1PH 230V, 50Hz, 1PH<br />

Output power 2 kVA 3,6 kVA<br />

5kVA at 20A industrial networks<br />

Motor connection <strong>10</strong>-poles: L1, N, 3*PE,U,V,W, PTC, FP, SGND Screw clamps 4mm2 Output voltage 3* 115V 3* 230V<br />

Output current electronically limited<br />

Over-current period can be regulated<br />

Output frequency<br />

Characteristic lines<br />

AC: 8.8kHz / 500,000 rpm DC: 60,000 rpm<br />

Of spindle max. 16, internally stored<br />

Spindle sensor inputs PTC, magneto-resistor, logic 9 <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong><br />

Control inputs 2 analog: 0-<strong>10</strong>V, galvanically separated: <strong>10</strong> <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong><br />

Control inputs 6 digital: 0-24V, galvanically separated: <strong>10</strong> <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong><br />

outputs 2 analog: 0-<strong>10</strong>V, galvanically separated: <strong>10</strong> <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong><br />

Control outputs 6 digital: relay outputs, 12 <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong><br />

24VDC/<strong>10</strong>00mA, 125VAC/500mA<br />

Interface USB, RS232, RS485, profibus D-Sub 9 pole pins<br />

Housing dimensions B 1<strong>10</strong> mm / H 275 mm / D 185 mm<br />

Weight approx. 4 kg<br />

Protection IP20<br />

Operating temperature 40°C<br />


6. Safety and Caution Instructions<br />

This device produces dangerous electrical voltages and is used for the operation of dangerously<br />

rotating mechanical parts. For this reason, only professionally qualified and trained personnel<br />

may work with this device and install it!<br />

Any work on the device may only be executed when the mains voltage has been turned off.<br />

Before the initial operation is carried out, it has to be made sure that the motor is firmly<br />

installed and can’t make any uncontrolled movements.<br />

Whenever working on the device, it has to be guaranteed that all of the safety regulations<br />

that are nationally valid are adhered to.<br />

Maintaining EMC (electromagnetic compatibility) limits is the responsibility of the<br />

manufacturer of the machine or the device. The inputs and outputs of this device are<br />

equipped with filters in order to increase interference immunity and to reduce emitted<br />

interference. Thus, the operation in an industrial environment is basically possible.<br />

The EMC of a machine or a device is influenced by all the connected components (motor,<br />

cable, wiring…). Under certain circumstances, the connection of external filters may be<br />

necessary in order to guarantee the adherence to the legal EMC regulations.<br />

For the above-mentioned reasons, the installation may only be carried out by qualified<br />

personnel.<br />

CAUTION: The operation of a spindle/motor with the wrong characteristic<br />

line can cause severe damage to the spindle/motor! Please make always<br />

sure that the correct characteristic line is chosen!<br />


SFU 0303<br />

7. View of Front Panel<br />


8. Connections, Plugs and Pin Assignments<br />

Operating parameters and outputs:<br />

The SFU-0303 collects all of the current important operating parameters and data. Of<br />

these, up to 6 parameters may be displayed at the digital outputs as a message and up<br />

to 2 analogue values (0-<strong>10</strong>V) may be emitted at the analog outputs.<br />

Remote control and inputs:<br />

There are 6 digital inputs (24V) and 6 analog inputs (0-<strong>10</strong>V) available for the remote<br />

control of SFU-0303.<br />

These assignments can be configurated freely. With the optional Windows PC software<br />

“SFU-Terminal” (>8.), the above-mentioned assignments can be made easily. Thus, an<br />

extremely flexible adjustment to the different applications is possible. Every operating<br />

parameter as a message and every control signal can be assigned to any I/0-pin. Moreover,<br />

the current logic level (high- or low-active) can be defined individually.<br />

The same assignment is also possible for the analogue performance data and control<br />

data to the analog I/0-pins.<br />

The standard assignment of operating parameters and related outputs and control signals<br />

and inputs is listed in the following chart.<br />


SFU 0303<br />

8.1 Digital and Analog Inputs X2 (<strong>10</strong> <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong>)<br />

14<br />

Pin Designation Direction Function / Message / Default Setting<br />

1 digital in 1 input start<br />

2 digital in 2 input Power stage pulse inhibitor<br />

3 digital in 3 input output stage off<br />

4 digital in 4 input interlock<br />

5 digital in 5 input error reset<br />

6 digital in 6 input direction of rotation<br />

7 analog in 1 input duty value for rotational speed <strong>10</strong>Vmin./max.<br />

8 analog in 2 input duty value for vario load<br />

9 GND reference ground for the signals<br />

<strong>10</strong> +24V/50mA output auxiliary supply<br />

For customer-oriented adjustments, different assignments of the input<br />

and output values may be valid. The assignment and the I/0 numbers<br />

can be freely programmed with the help of the software.<br />

Switch level digital inputs: 0...7V=Log "O"/18...24V=Log"1"<br />

The "hi" level for the digital inputs 24 V (SPS standard level).<br />

Analog input voltage range: 0...<strong>10</strong>V<br />

The +24V at pin <strong>10</strong> may be used as an auxilary supply e.g. for an<br />

electronic spindle interface.

8.2 Digital and Analog Outputs X3 (12 <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong>)<br />

Pin Designation Direction Function / Message / Default Setting<br />

1 relay common common bar relay connections<br />

2 relay 6 normally closed contact output feedback on pulse inhibitor 3<br />

3 relay 5 normally closed contact output over-temperature converter or spindle<br />

4 relay 4 normally closed contact output overload<br />

5 relay 3 normally closed contact output standstill converter + spindle<br />

6 relay 2 normally closed contact output<br />

7 relay 2 normally open contact output spindle ready<br />

8 relay 1 normally closed contact output<br />

9 relay 1 normally open contact output converter ready<br />

<strong>10</strong> analogue out 1 output<br />

11 analogue out 2 output<br />

12 output magneto resistor output square signal of rotary encoder<br />

X3<br />

2<br />

1<br />

12<br />

11<br />

<strong>10</strong><br />

9<br />

8<br />

7<br />

6<br />

5<br />

4<br />

3<br />

2<br />

1<br />

9<br />

For customer-specific adjustments, other assignments of the input<br />

and output values may be valid. The assignment and the I/0 numbers<br />

are freely programmable with the help of the software.<br />

The digital outputs (relay 1…6) are electrically isolated (500V<br />

isolation). DC: 24V / <strong>10</strong>00mA; AC: 125V / 500mA<br />

Output level hall sensor magneto resistor: 0-24V (24V level)<br />

The GND for Pin <strong>10</strong>,111, 12 is X2.9<br />


SFU 0303<br />

8.3 Spindle Interface X4 (9 <strong>pluggable</strong> <strong>screw</strong> <strong>terminals</strong>)<br />

Pin Name Direction Function<br />

1 +12V/50mA output auxiliary voltage<br />

2 S/GND ground for spindle interface signals<br />

3 NC Not connected<br />

4 rotary encoder input input input for two-/three-wire magneto resistors<br />

5 PTC input temperature signal of spindle<br />

6 bit 4input automatic spindle recognition<br />

7 bit 3 input automatic spindle recognition<br />

8 bit 2 input automatic spindle recognition<br />

9 bit 1 input automatic spindle recognition<br />

3<br />

2<br />

For customer-specific adjustments, other assignments of the input<br />

and output values may be valid.<br />

1<br />

Inputs for automatic spindle recognition can also be used for external<br />

characteristic line switching of the spindle.<br />

16<br />

X4<br />

9<br />

8<br />

7<br />

6<br />

5<br />

4<br />

3<br />

2<br />

1<br />

The spindle interface is electrically isolated from all the other signals<br />

via optocoupler. It may be used for automatic spindle recognition if<br />

it is activated. The logic levels are in a default way LOW-active: Hi ><br />

pin on spindle S/GND, Lo > pin open. In the menu “Digital Inputs”<br />

this may be changed.<br />

The input PTC is intended for the recognition of over-temperature at<br />

the spindle. If the resistance between PTC and GND is > 600 ohm, the<br />

error message "over-temperature spindle" is activated and a safety<br />

cutoff is executed after an adjusted delay.<br />

The input FP for the rotary encoder or the hall sensor respectively works<br />

in the range of +/- 1V with a common mode range of 0..<strong>10</strong>V.<br />

The +12V at pin 9 may be used as auxiliary voltage, e.g. for an active<br />

magneto resistor.

8.4 Mains connection, Spindle Connection with<br />

Plug Connectors<br />

8.5 Screw Clamp Connectors<br />

Auxiliary supply for active magneto resistor 12V/50mA<br />

Ground for PTC, Mr<br />

Rotary encoder spindle magneto resistor / hall sensor<br />

Spindle PTC<br />

Spindle phase W<br />

Spindle phase V<br />

Spindle phase<br />

External braking resistance / chopper resistor<br />

Intermediate circuit voltage<br />

Protective Earth<br />

Protective Earth<br />

Neutral<br />

Mains phase<br />

CAUTION:<br />

Use control cables, power lines<br />

and motor cables separately.<br />

Use shielded cables.<br />


SFU 0303<br />

8.6 RS 232, RS 485<br />

Un<strong>screw</strong> with 2.5mm Allen key<br />

8.7 USB Connection<br />

18<br />

The connection to the PC via RS232<br />

and RS 485 is made with previously<br />

configurated <strong>BMR</strong> cables.<br />

USB connecting cable see<br />

point 20 "Accessories"<br />

For connection and communication with a<br />

PC it is implemented an USB interface on the<br />

operating panel<br />

USB Mini AB<br />

(enlarged picture)

9. Description of Function, Setup, Operation<br />

The series 0303 is equipped with a safe pulse inhibitor which must be operated<br />

correspondinglyto use. To activate the output stage, you must connect a voltage of 24V to<br />

the digital input 2. The feedback from the converter on the condition of the pulse inhibitor<br />

is made, if existent, on the display of the control unit and on the digital output 6 of plug<br />

X3. Without this adjustment, the device cannot be set up.<br />

The power stage pulse inhibitor corresponds to the directives category 3 EN954-1/ for the<br />

safety of actuators and in addition to that has a feedback on the condition via the output<br />

relay 6, pin 2 bar X3.<br />

Before the first use, it has to be guaranteed that the correct characteristic line is activated<br />

for the connected motor. This is the case when the device with motor has been bought<br />

from the producer as a system and when the necessary preadjustments have been stored.<br />

In case of doubt, characteristic lines for all current spindle are available at <strong>BMR</strong>.<br />

If a spindle with an unknown characteristic line is connected, it is easy to identify a<br />

characteristic line with the help of the SFU Terminal software (-> point <strong>10</strong>).<br />


SFU 0303<br />

9.1 Starting the Converter<br />

There are several possibilities of starting the converter. It is generally valid that only the starter<br />

itself can again also cause the order to stop, unless a higher-ranking emergency OFF or a safety<br />

function causes the stop.<br />

20<br />

Start button at LCD control panel, rotation speed via rotary encoder<br />

Exclusively digital control via the RS232/RS485/USB/profibus interface<br />

Digital input together with an analog input for control of rotation speed. If no analog input<br />

is enabled for the control of the rotation speed, the rotation speed is provided by the rotary<br />

encoder at the control unit or via the RS232/RS485/USB/ profibus interface.<br />

Requirement for the correct starting performance is a correctly activated, enabled pulse<br />

inhibitor as well as the correct characteristic line for the connected motor.<br />

If the control unit is plugged in, the status messages are made via the LCD display in plain<br />

text. The status messages are always shown via the LED panel:

9.2 Status Informationen of LED Display<br />

1 2 3<br />

STATUS<br />

4 5 6<br />

LED 5: converter and<br />

spindle ready<br />

1 2 3<br />

STATUS<br />

4 5<br />

1 2<br />

6<br />

LED 2, 4 and 5:<br />

excess temperature<br />

spindle<br />

3<br />

STATUS<br />

4 5 6<br />

LED 3: Emergency OFF<br />

and/or interlock activated<br />

1 2 3<br />

STATUS<br />

4 5 6<br />

LED 2 and 5: converter<br />

o.k., spindle working<br />

1 2<br />

STATUS<br />

4 5<br />

3<br />

6<br />

LED 1, 2, 4 and 5:<br />

excess temperature<br />

spindle + overload<br />

1 2 3<br />

STATUS<br />

4 5 6<br />

LED 6: pulse inhibitor<br />

activated<br />

1<br />

STATUS<br />

4 5 6<br />

STATUS<br />

4<br />

2<br />

LED 1, 2 and 5:<br />

overload<br />

3<br />

1 2 3<br />

5 6<br />

LED 2 and 4:<br />

excess temperature<br />

converter<br />

1 2 3<br />

STATUS<br />

4 5 6<br />

LED 1, 3, 4 and 6:<br />

earth connection<br />

When the message “converter and spindle ready” appears, the start can be activated. Different<br />

measures for trouble shooting are discussed in the appendix. The most common error source<br />

is an emergency OFF which has not been handled, interlock or the pulse inhibitor. In these<br />

cases, it is recommended to control the adjustments in the "digital starting" menu in the SFU<br />

Terminal and to check if all releases are operated correctly.<br />


SFU 0303<br />

9.3 LCD Operating Panel<br />

CAUTION: The operation of a spindle / a motor with an incorrect<br />

characteristic line can lead to severe damages of the spindle / the motor!<br />

Please make always sure that the correct characteristic line has been chosen!<br />

If several spindles are operated simultaneously, it has to be safeguarded that they are<br />

of the same type and that the correct characteristic line has been chosen for them!<br />

Otherwise, this can lead to the damage of one or several spindles, as the operating<br />

voltage of the spindles can vary extremely!<br />

22<br />

In the easiest case, the connected spindle is started with the START button. The set rotation<br />

speed can be pre-selected with the rotary encoder and can be changed variably at any time<br />

during the operation. For a correct start, the terms of points 9 and 9.1 “Setup and starting<br />

performance” are valid.<br />

All relevant system messages on rotation speed, load or troubles are made via the LCD<br />

display on the operating unit.<br />

The power released at the moment is shown in the lower part of the LCD as an analog bar<br />

chart and as an absolute value in %. In the case of overload, this is also shown.<br />

The pre-selected set rotation speed, the selected characteristic line of the spindle and the<br />

momentary actual rotation speed of the spindle are shown.<br />

In the case of a failure, the kind of error is shown in the text display.<br />

Standstill ! 3<br />

forw > 25000 rpm<br />

Conv&Spin ready!<br />

Characteristic line 3 of spindle<br />

selected<br />

Duty speed ok. 3<br />

forw > 25000 rpm<br />

-------------- 67%<br />

Spindle rotates with set rotation<br />

speed Power output 20%<br />

Vorlage Englisch fehlt<br />

3<br />

Outp. 7830 rpm<br />

-------- 67%<br />

Converter accelerated<br />

Power output 67%<br />

Overload 3<br />

Outp.> 25000<br />

Conv. not ready<br />

In the case of a failure, the kind of error is<br />

shown in the plain text in the first line.<br />

Vorlage Englisch fehlt

The following error displays are possible:<br />

Pulse inh. act.! Error pulse inhibitor activated<br />

Overload stop Error overload<br />

Excess temp. conv. +spn Error excess temperature converter<br />

Excess temp. spin. Error excess temperature spindle<br />

Excess temp. conv. +spn Error excess temperature or spn. conv.<br />

Overvolt. off! Error overvoltage off<br />

Undervolt. off! Error undervoltage off<br />

Undervolt. stop! Error undervoltage stop<br />

Output st. off Error output stage switched off<br />

Emergency Off act.! Error emergency OFF entry locked<br />

Without spn. cable Error without spindle or cable break<br />

RS232 error! Error timeout ser. interface<br />

Char. line error:! Error characteristic line invalid!<br />

Encoder error:! Error in the rotary encoder / hall sensor<br />

Entry option:<br />

Stop button Menu button Start button<br />

integrated in<br />

the rotary encoder<br />

Normal display:<br />

Line 1: Status<br />

Line 2: Rotation speed / direction of rotation<br />

Line 3: Load display %, progress bars<br />

Green LED for start/run<br />

Red LED for stop condition<br />

Continued on page 24<br />


SFU 0303<br />

9.3 LCD Operating Panel<br />

Adjustments:<br />

Adjustment of rotation speed: turn left/right via rotary encoder. The set rotation speed is<br />

always shown during the adjustment.<br />

Start/stop: Via start/stop button. If the operating unit is removed during the start condition,<br />

the converter automatically turns to stop condition.<br />

Menu selection: Keep pushbutton in the rotary encoder pushed for more than 1 sec. The<br />

following selection appears:<br />

Direction of rotation Ri/le<br />

Selection of char. lines Characteristic lines 1..16 are shown in the plain text<br />

Debug mode Display of mains voltage/power and spindle voltage for 30s<br />

Version info No. of current version and software date on line 2 for 5sec<br />

Language German/English<br />

Contrast Set contrast with rotary encoder ri/le<br />

ESC Quitting the menu<br />

With the rotary encoder, a menu item can be selected, the active entry is flashing. By pushing<br />

the menu pushbutton, the final entry is selected. With ESC the menu is quitted without changes.<br />

After approx. <strong>10</strong> sec without activity, the display returns to standard mode.<br />

The adjustment of the direction of rotation and the selection of the characteristic line are only<br />

possible during standstill.<br />

Special function:<br />

During the operation, the debug mode can<br />

be switched on/off by briefly pushing the<br />

menu button. The mains voltage, output<br />

current and spindle voltage are displayed.<br />

The display automatically returns to standard mode after approx. 30sec.<br />

24<br />

Mains: 318 V<br />

Curr: 5,1 A<br />

Spnd: 78 V

9.4 Adjustment of Rotation Speed<br />

The preselection of the rotation speed can be made in two ways:<br />

Manual preselection via the menu buttons<br />

For this, the option button 0 in the line set rotation speed must be clicked on in the menu<br />

“Analog Inputs” of the SFU Terminal software. Thus, all analog inputs are switched on<br />

passive and no analog start signal is selected. The set rotation speed is shown on the LCD<br />

display and can be altered with the rotary encoder the increase of the rotation speed<br />

depends on the rotation speed of the rotary encoder. The rotation speed may also be altered<br />

during the operation.<br />

Preselection via analog input set rotation speed<br />

For this, an analog input must be assigned to this function in the menu "Analog Inputs"<br />

of the SFU Terminal software. In addition to that, a scaling must be made from rotation<br />

speed to analog value in the corresponding edit field for set rotation speed (e.g.: 1V/<strong>10</strong>,000rpm<br />

or 0-<strong>10</strong>V min/max).<br />

The set rotation speed corresponding to the applied voltage and scaling is shown on the<br />

LCD display and can be changed at will.<br />

An input voltage of 0V leads to a standstill and the feed of a voltage >0V leads to the starting<br />

or adjustment of a rotation speed corresponding to the selected scaling. For the above<br />

mentioned scaling, a rotation speed of 40,000rpm is adjusted for e.g. 4V.<br />

The selected adjustments must be written into the converter with the button<br />

Only write parameters into the converter.<br />


SFU 0303<br />

9.5 Safety Functions<br />

The below-mentioned adjustments of the menus refer to the SFU Terminal software.<br />

The following incidents lead to a controlled braking according to the specified acceleration<br />

data of the spindle, as they are established in the characteristic line for this spindle.<br />

26<br />

Stop because of excess temperature at the spindle, if this function is activated and if the<br />

corresponding delay time (can be adjusted in the menu “Delays…excess temperature<br />

spindle”) has been exceeded.<br />

In the menu “Spindle”, this function can be activated with the check button Temp. Sensor,<br />

and the delay time can be adjusted in the menu “Delays”.<br />

Stop because of excess temperature of the converter after the corresponding delay time<br />

has expired. Adjusted in the menu “Delays… excess temperature converter”.<br />

Stop because of overload after expiration of the allowed delay time. The parameters for the<br />

overload criteria are determined in the characteristic line. Normally, you take the power<br />

value <strong>10</strong>0% for the S1 operation. About <strong>10</strong>% more for the overload criterion, about 30%<br />

more for the S6 operation, and as delay overload approx. 20sec.<br />

Immediate stop because of exceedance of the maximal power of the converter.<br />

Emergency stop via signal at the digital input Interlock.<br />

Adjusted in the menu “Digital Inputs”.<br />

The following incidents lead to a cut off of the output stage. The spindle is slowed down<br />

only by its own load. Depending on the centrifugal mass, it can take a very long time until<br />

the standstill has been reached. We recommend a rotary encoder in the spindle for a secure<br />

recognition of the standstill.<br />

Stop because of a short circuit at the spindle connection leads to a cut off of the output<br />

stage. This is determined by internal limiting values for the maximal power of the converter.<br />

Stop via signal at the digital input Output Stage Off. Adjusted in the menu “Digital Inputs”.<br />

A re-start can only be made through a systematic stop/start sequency or through the feed<br />

of a valid signal at the digital input Error Reset. Adjusted in the menu “Digital Inputs”. In<br />

this case, the output stage is connected again after 4 sec.

9.6 Safe Pulse Inhibitor according to EN 954-1 K3<br />

The SFU-0303 is equipped with a safe pulse inhibitor for power stage according to category 3.<br />

The diagram shows a possibility of connection together with a PLC:<br />

Safe pulse inhibitor according to EN 954-1category3:<br />

For test purposes only, a bridge circuit can be added between terminal X2.2 and X2.<strong>10</strong>. Then<br />

the converter is running, but it may not be used in equipments which must be certified<br />

according to EN 954-1.<br />

<strong>10</strong>. Profibus Connection<br />

Safe pulse inhibitor according to<br />

EN 954-1 category 3<br />

Condition pulse inhibitor<br />

activated, converter is in a safe<br />

situation.<br />

Level at terminal X3.2 for this<br />

condition is “low”.<br />

A profibus DP connection conforming to standards is available as an option.<br />

The interface is integrated in the special version of the operating panel.<br />

The adjustment of the profibus address is made via RS232 connection cable and SFU Terminal<br />

Program.<br />

The corresponding data plus command interpreter for the integration, e.g. into the S7 by<br />

Siemens, can be found on the website in the download options under “<strong>BMR</strong>-GSD”.<br />

It is always possible to make the adjustments with adapter cable and RS232 via the terminal<br />

program.<br />


SFU 0303<br />

11. Setup, Configuration with Windows<br />

Software<br />

The SFU Terminal Software is a convenient tool for the configuration of frequency converters<br />

of the series SFU 0<strong>10</strong>2 up to SFU 0601. Moreover, it also offers the possibility of reading system<br />

data and of parameterising them. For this purpose, the following steps should be taken:<br />

1. Switch on the converter and make the connection via USB or the RS232.<br />

2. Start the program SFUTerminal.EXE<br />

The description is stored in the Help File, and can be found in the Manual<br />

"SFU Terminal Software".<br />


12. Automatic Calibration of Spindles and Adjustment<br />

of the Corresponding Characteristic Curves<br />

For this purpose, the converter is connected with a PC via USB or RS 232. The connection<br />

can be made with an appropriate <strong>BMR</strong> RS232 cable or with a LCD operating panel with<br />

USB connection. Now the software "SFU Terminal" may be started. At first, the data of the<br />

converter are read out automatically.<br />

Now choose "Tools" - "Automatic Diagram" in the menu bar.<br />

CAUTION:<br />

Damages to the motors or converters due to incorrect entries or incorrect<br />

operations are outside of any warranty claims!<br />

Continued on page 30<br />


SFU 0303<br />

12. Automatic Calibration of Spindles and Adjustment<br />

of the Corresponding Characteristic Curves<br />

Example 1, normal adjustment:<br />

A 2-pole motor has a nominal voltage of 220V with a current of 5A with a maximal rotation<br />

speed of 30,000 rpm at 30,000 rpm.<br />

For the S1 operation, the nominal current is adjusted to 5A and the current limit for the<br />

S6 operation is adjusted to 8A.<br />

Example 2, field suppression:<br />

A 2-pole motor has a nominal voltage of 220 V with a current of 5A with a maximal rotation<br />

speed of 30,000 rpm at 20,000 rpm.<br />

30<br />

At first, only the characteristics of the motor must be entered. It is important that the correct<br />

nominal voltage for the rotation speed is indicated. The reason for this is that motors can<br />

also be operated in the field suppression, so that they can reach a higher rotation speed<br />

than the actual nominated rotation speed. 12.000/sec should be adjusted as acceleration<br />

values (Ramp up/down). It has to be safeguarded that the spindle can move freely on the<br />

motor.<br />

The automatic calibration is made by clicking on "Start Automatic". After a successful run,<br />

store the characteristic curve and adopt it into the converter.

13. Examples of Connections<br />

13.1 Logic and Safety Circuit<br />

X2<br />

X3<br />

<strong>10</strong><br />

9<br />

8<br />

7<br />

6<br />

5<br />

4<br />

3<br />

2<br />

1<br />

12<br />

11<br />

<strong>10</strong><br />

9<br />

8<br />

7<br />

6<br />

5<br />

4<br />

3<br />

2<br />

1<br />

The spindle interface X4 is not wired here as the use depends very strongly on the configuration<br />

of the spindle and on the different characteristic lines.<br />

This interface should only be used in combination with the automatic spindle recognition<br />

after prior consultation with <strong>BMR</strong>.<br />

By assigning the four address lines, a characteristic line can be pre-selected in the spindle<br />

via the SPS or external switches/plugs, as soon as this function has been enabled by the<br />

SFU terminal software.<br />

Continued on page 32<br />


SFU 0303<br />

13.1 Logic and Safety Circuit<br />

13.2 Mains and<br />

Spindle Connection<br />

32<br />

The digital feed can also be realized via outputs of programmable logic devices, with a<br />

starting high level >20V. The chart shows a configuration with passive switches and the<br />

internal voltage feed through the converter.<br />

For stabilizing the analog standard of the rotation speed, a voltage regulator 78L<strong>10</strong> is<br />

recommended. In connection with a SPS, one usually takes a D/A converter output with<br />

0-<strong>10</strong>V.<br />

The outputs are executed in such a way that the logic levels 0V and +24V are generated by<br />

the electrically isolated relays. For any other arrangement, the relay contacts can be wired<br />

and used freely. In the arrangement shown above, the logic level is assigned to the GND<br />

of the converter. The outputs shown in the diagram can be used directly as feed into a SPS.<br />

Description of starting performance with enabled analogue input:<br />

Enabling via input “dig. start”, the motor starts when the analog standard rotation speed<br />

becomes higher than the minimal rotation speed (you can see this in the corresponding<br />

spindle diagram in the area “min. rotation speed”) and continues when either input start<br />

turns to low or when the standard rotation speed becomes lower than the minimum rotation<br />

speed. If e.g. <strong>10</strong>V is fed on analog input 1, the motor starts when the digital input 1 turns<br />

to high. In this case, the motor accelerates to the maximal rotation speed.<br />

Brake Resistor<br />

Speed sensor

14. EMC<br />

This device was developed for the operation in an industrial environment. For a troublefree<br />

operation and in order to reduce the emitted interference, the following hints should<br />

be observed when wiring:<br />

The EMC of a machine or a device is influenced by all of the connected components (motor,<br />

cable, wiring…). Under certain circumstances, the connection of external filters may be<br />

necessary in order to guarantee the adherence to the legal EMC standards.<br />

The earth and shield connections of all the devices used in interconnection with the converter<br />

should be as short as possible and have as large a cross-section as possible.<br />

Control units (SPS, CNC, IPC…) connected to the converter should be connected to a<br />

common earth terminal bar.<br />

Use serrated lock washers for the mechanical assembling in order to safeguard a good<br />

electrical contact with the housing.<br />

All connections to and from the converter should be made with shielded cables. Earth the<br />

shield on both sides.<br />

Power lines, motor lines and control lines should be laid separately on principle. When<br />

crossings can’t be avoided, they should be executed at a 90° angle.<br />

Lay the control wires as far away from the load wires as possible.<br />


SFU 0303<br />

15. Troubleshooting<br />

Description of Error<br />

When starting the SFU Terminal, the<br />

converter isn’t found or the data<br />

communication is defective:<br />

The LCD display shows “Spindle not<br />

ready”<br />

34<br />

Cause of Error, Corrective<br />

The converter must be switched on.<br />

Only original cables by <strong>BMR</strong> may be used.<br />

USB cables shouldn’t be longer than 2m.<br />

The cause is often an entry in the system<br />

configuration of Windows. If the device manager<br />

shows the Com Port No>12, it is recommended<br />

to place the no. manually on the next free place<br />

with the lowest no. (3 or 4…).<br />

Check if the PTC in the spindle is defective or if<br />

there is an excess temperature in the spindle.<br />

Has the PTC been connected correctly (see Point<br />

9. Example of Connection)?<br />

Has the spindle been connected properly (see<br />

Point 9. Example of Connection)?

Description of Error<br />

The LCD display shows “Converter not<br />

ready”<br />

The spindle cannot be started via dig.<br />

input, although “Converter” and<br />

“Spindle” are ready:<br />

Cause of Error, Corrective<br />

Excess temperature converter may be activated<br />

(if this is the case, check if the ventilator works<br />

without fault).<br />

The hardware current limiting has acted – actuate<br />

error reset via Start, after release check if the<br />

spindle has blocked, before you start again.<br />

The general current limiting has acted, a new start<br />

is possible after error reset (via Start or digital<br />

pin).<br />

A digital input “Interlock”, “Pulse inhibitor” or<br />

“Emergency OFF” is still activated – check the<br />

inputs.<br />

An invalid characteristic line has been chosen –<br />

check if the no. of the characteristic line<br />

corresponds to the type of spindle.<br />

When the magneto resistor is activated and the<br />

MR-input shows failures (e.g. with an open input),<br />

the spindle cannot be started – check the MRconnections.<br />

When an analogue input has been activated<br />

(Menu “Analogue Inputs”), the spindle will only<br />

start with the analogue voltage corresponding to<br />

the minimum rotation speed, if the digital input<br />

for “Start” is activated at the same time. When the<br />

green LED on the front panel flashes and the<br />

spindle doesn’t rotate, maybe the motor cable<br />

was drawn off after starting the converter.<br />

Continued on page 36<br />


SFU 0303<br />

15. Troubleshooting<br />

Description of Error<br />

The display shows “Characteristic line<br />

error xx”:<br />

The message “Actual rotation speed<br />

reached” disappears and “Set rotation<br />

speed o.k.” appears with a higher<br />

rotation speed. The message<br />

"Encoder error" appears.<br />

The message “Without spindle.., cable”<br />

appears, although a spindle has been<br />

connected:<br />

36<br />

Cause of Error, Corrective<br />

An invalid characteristic line has been chosen, a<br />

valid characteristic line can be chosen with the<br />

control panel or with the SFU Terminal Software.<br />

Restart with ESC or switching off/on of the<br />

This is probably a failure of the rotary encoder.<br />

There are either disturbances on the signal or the<br />

signal level isn’t appropriate.<br />

Check three phases and motor cable respectively.<br />

Maybe a wrong characteristic line has been chosen.<br />

The self test when starting takes as an inspection<br />

value the adjustment of the adjusted spindle<br />

diagram. If an inappropriate type of spindle has<br />

been chosen, maybe the inspection current is too<br />

low, and the spindle isn’t accepted.<br />

Check characteristic line, type of spindle.<br />

With an adjustment in the Terminal Software (box<br />

“Spindle test” in the Terminal Software, main<br />

form), this spindle test can be skipped. However,<br />

this is not recommended if the spindle test is to<br />

be used as a safety function.

16. Mechanics, Views, Dimensions<br />


SFU 0303<br />

17. EG Declaration of Conformity<br />

38<br />

Manufacturer: <strong>BMR</strong> GmbH<br />

Unterreichenbacher Str. 1<br />

90455 Nuernberg<br />

Product: SFU 0303<br />

The above mentioned products comply with the regulations of the following European<br />

guidelines:<br />

89/336/EWG approximation of legal regulations on EMC"<br />

The adherence to the above mentioned guidelines requires an installation into the<br />

total unit according to the EMC.<br />

The following standards are applied:<br />

EN 61800-3<br />

C3 standards which are also complied with:<br />

VDE 0839 Teil 6-4, IEC 6<strong>10</strong>00-6-4<br />

VDE 0160 Teil <strong>10</strong>0, IEC 61800-3<br />

VDE 0847 Teil 4-8, IEC 6<strong>10</strong>00-4-8<br />

VDE 0847 Teil 5-5, IEC 6<strong>10</strong>00-4-5<br />

VDE 0875 Teil 11 + Bbl. 1, IEC / CISPR 11 (CISPR TR 28)<br />

VDE 0847 Teil 4-6, IEC 6<strong>10</strong>00-4-6<br />

VDE 0847 Teil 4-2 +A1, IEC 6<strong>10</strong>00-4-2 +A1<br />

VDE 0847 Teil 4-11, IEC 6<strong>10</strong>00-4-11<br />

VDE 0847 Teil 4-3, IEC 6<strong>10</strong>00-4-3 +A1<br />

VDE 0839 Teil 6-2, IEC 6<strong>10</strong>00-6-2<br />

VDE 0847 Teil 4-4, IEC 6<strong>10</strong>00-4-4<br />

Nuernberg, April 12, 2008<br />

Rudolf M. Brittling, executive director<br />

Electric drives with variable rotation speed<br />

EMC product standard including special<br />

test procedures

18. General Hints<br />

Our frequency converters are highly valuable precison devices. Please take care of<br />

them with the necessary attention, to preserve their high precision, high power ability,<br />

and long lifetime.<br />

These devices leave our company only after a quality test and a load check have<br />

been carried out. Before mounting and use please read the attached manual carefully and<br />

pay attention to the points listed below.<br />

Before the first activation of the device, verify if it is in a faultless optical condition.<br />

If it was damaged during transportation, it must not be used and not turned on.<br />

During the installation the safety regulations must be observed.<br />

Before the converter is turned on for the first time, it should be verified that<br />

connected parts cannot carry out uncontrolled movements.<br />

The frequency converter must not be operated close to heating devices or<br />

magnetic devices.<br />

Sufficient air circulation around the converter should be ensured.<br />

Fluids should be prevented from intruding into the housing.<br />

If it seems to have happened, the converter has to be switched off immediately.<br />

If the converter is connected to a remote control, it should be verified that the<br />

switch is in the OFF position before connecting.<br />

All repairs and maintenance on our converters must be carried out by skilled and instructed<br />

persons, only.<br />

All repairs and maintenance on the converter and the relating accessories must be carried<br />

out by skilled and instructed persons in the OFF-state only. To ensure this, the mains plug<br />

should be pulled out. In doing this, both the terms of regulations for preventing accidents<br />

and the general and national rules for mounting and safety have to be applied.<br />

Our common hints can give only a rough guideline because it is not possible for <strong>BMR</strong><br />

to deal with every specific situation. The compliance with the limits of EMC demanded<br />

by law is the responsibility of the manufacturer of the unit or machine. By doing<br />

controls and tests in our own laboratory, <strong>BMR</strong> can guarantee that our products comply<br />

with the corresponding standards if they are installed and used in an appropriate<br />


SFU 0303<br />

19. Warranty<br />

With exclusion of additional claims we give a warranty on our Frequency Converter for 1 year<br />

on errors due to material, mounting and construction.<br />

We commit to repair or replace the parts without any costs which seem to be<br />

defective by our estimation and which are not damaged by not appropriate handling.<br />

Warranty claims have to be sent to us in written form. The customer has to pay the costs to<br />

send the defective device back to <strong>BMR</strong> within the time of warranty. If this is not complied with<br />

or if we detect an external intrusion into our control unit, we withdraw our duty of warranty.<br />

Our duty of warranty is limited to the repairing or replacing of the defective parts.<br />

We refuse claims of responsibility or warranty for direct or indirect consequential<br />

damages, caused by faults of our products.<br />

Changes in construction may be carried out without any message or notification.<br />

Our common terms of business conditions apply.<br />

Subject to technical changes.<br />

40<br />

<strong>BMR</strong> GmbH is a dynamic and flexible company. We take into account specific<br />

requirements of our customers as well as demanding solutions in design. These<br />

are integrated according to qualitative and functional aspects maintaining of<br />

course our high quality standard.<br />

Our company is working according to the highest economical and ecological<br />

standards which are mirrored at <strong>BMR</strong> in all areas. Especially in manufacturing<br />

we try to improve our ecological standard constantly. It has been and is our<br />

constant purpose to comply with these demands. Due to our constant efforts<br />

we obtained in 1998 the certification according to DIN ISO 9001 for Quality<br />

Management Systems.

20. Accessories<br />

RS 232 P 2001.<strong>10</strong>0012<br />

USB-cable P 2001.<strong>10</strong>0013<br />

RS 485-cable P 2001.<strong>10</strong>0014<br />

Mounting bracket for the laying of cables + clamps P <strong>10</strong>01.<strong>10</strong>0006<br />

Mounting brackets for housing A 1700.504133<br />

Kit of clamps P <strong>10</strong>01.<strong>10</strong>0005<br />

LCD-control unit P 1203.<strong>10</strong>0003<br />


42<br />

The company <strong>BMR</strong> GmbH was founded in 1978.<br />

We develop, construct and manufacture electronic devices<br />

and electronic drive units.<br />

Nearly all the steps of the manufacturing process are carried<br />

out within our company.<br />

The development department designs all our printed circuit<br />

boards first in a schematic form and then as a layout. They<br />

furthermore develop the firmware for the microcontrollers and<br />

DSPs and even the Windows PC Software for our devices.<br />

The manufacturing department solders and mounts<br />

all the components. And finally in the quality and test<br />

department the devices are tested and set up according<br />

to the customers requirements.<br />

We have established "short ways" between the departments in<br />

order to guarantee a constant level of high quality and to be able<br />

to realize changes fast and in a flexible way.<br />

By keeping the manufacturing processes within our company,<br />

we have gained years of knowledge and experience,<br />

offering this further to our customers as an extra service.<br />

Our goal is a quick,<br />

flexible und reliable execution of orders.<br />

With our long-time experience, especially in manufacturing<br />

frequency converters, we have gained a strong position in the<br />

market. This becomes evident especially in our<br />

growing presence in domestic and overseas markets.

Our present<br />

product profile:<br />

High frequency converters for industrial use<br />

Drive units for Electroluminescence displays<br />

intelligent lighting controls<br />

Control units for domestic appliances<br />

Acoustic test units<br />

Motor controls<br />

Accumulator charger<br />

Time controls, for example grease controls used in<br />

automotive applications<br />

Development of oem controls<br />

Manufacturing of electronic devices using wire-through<br />

and surface mount technique<br />

We also work as an extended workbench for<br />

well known companies<br />


Our strength<br />

is called quality!<br />

The quality sign "Made in Germany" is the synonym for precision,<br />

reliability and innovation.<br />

<strong>BMR</strong> GmbH feels commited to these values. With two decades of<br />

experience in the sector of developing, constructing and<br />

manufacturing electronic devices and controls this was and still is<br />

the prescription for our success.<br />

Our policy of "short ways" ensures constant high quality. This makes<br />

it possible to react rapidly, in time and flexible with changes and<br />

requirements for our products.<br />

This concept is valued by our customers and becomes evident in<br />

our steadily growing presence in the market at home and abroad.<br />

If you are interested in our products and accessories, contact us or<br />

visit us on our website:<br />

www.bmr-gmbh.de<br />

<strong>BMR</strong> GmbH<br />

Unterreichenbacher Strasse 1<br />

90455 Nuernberg-Katzwang<br />

Germany<br />

Phone: .. +49(0)9122 / 63148-0<br />

Fax:........+49(0)9122 / 63148-29<br />

e-mail: info@bmr-gmbh.de<br />

www.bmr-gmbh.de<br />

Our Partner in the U.S.A.<br />


HPT Precision Spindles & Drives Inc.<br />

1<strong>10</strong> Newport Center Drive<br />

Suite 200 Newport Beach, CA. 92660<br />

USA<br />

Tel. ............(001) (949) 719-1145<br />

Fax:............(001) (949) 719-1150<br />

e-mail: sales@hpt-drivesystems.com<br />


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