10 pluggable screw terminals - BMR Gmbh

BMR GmbH 2009
MANUAL
Picture shows version SSE, for further available models, see point 3, page 8.

SFU 0303
2
Congratulation
for purchasing a BMR-GmbH product.
We thank you for the decision for
choosing a BMR-GmbH device
and wish you much success.
Please read
this manual carefully
before the first use
Version 18.Feb.2009

Contents:
1. Introduction 4
2. Description and Features 6
3. Specifications of Device 8
4. Block Diagram 9
5. Technical Data 10
6. Safety and Caution Instructions 11
7. View of Front Panel 12
8. Connections, Plugs and Pin Assignments 13
8.1 Digital and Analog Inputs X2 14
8.2 Digital and Analog Outputs X3 15
8.3 Spindle Interface X416
8.4 Mains Connection, Spindle Connection with Plug Connectors 17
8.5 View of Strip Terminal 17
8.6 RS232, RS485 18
8.7 USB Connection 18
9. Description of Function, Setup, Operation 19
9.1 Starting the Converter 20
9.2 Status Information of LED Display 21
9.3 LCD Operating Panel 22
9.4 Adjustment of Rotation Speed 25
9.5 Safety Functions 26
9.6 Safe Pulse Inhibitor according to EN 954-1 K3 27
10. Profibus Connection 27
11. Parametrisation, Configuration with Windows Software 28
12. Automatic Calibration of Spindles and Adjustment 29
13. Examples of Connections 31
13.1 Logic and Safety Circuit 31
13.2 Mains and Spindle Connection 32
14. EMC 33
15. Troubleshooting 34
16. Mechanics, Views, Dimensions 37
17. EC Declaration of Conformity 38
18. General Hints 39
19. Warranty 40
20. Accessories 41
3

SFU 0303
1. Introduction
Due to its construction, the rotation speed of a 3-phase AC motor is directly dependent on
the frequency of the connected network and on the number of poles. In the case of a network
frequency of 50 Hz and a 2-pole motor, the nominal rotation speed is 50 r/s * 60 = 3000 rpm.
In the case of DC motors (brushless DC), the rotation speed is dependent on the voltage
applied.
AC-Spindles offer a variety of advantages in the industrial area, such as brushless operation,
no wear and tear, favourable capacity/weight ratio, high rotation speed, and much more.
Accordingly, they can be used in a variety of areas, such as in milling and grinding spindles
or in drilling machines.
The advantages of SFU0303 compared to similar frequency converters:
4
Safe pulse inhibitor, authorized according to current regulations of EN 954-1 category 3
In an industrial network an output of up to 5kVA
High efficiency because of symmetrical PWM
Real time vector control for operation without sensor
Maximal torque even with a very low rotation speed
Highest acceleration times can be achieved for low process times, e.g. 25.000 rpm/sec for
a 2.2 KW motor (e.g. for robot applications in process technology)
PAM control possible through regulated intermediate circuit (optional)
Very low rotation speed (10 rpm) possible e.g. for the start of tool change positions
Lowest possible power input through real time power control system
Optimal integration into existent programmable controllers through open I/0 configuration
Interface to profibus, RS485, RS232, USB
Datalogger (optional) integrated through PC software. Recording of any length of all
relevant parameters in the converter possible. Ideal for the setup of the processing step

Autotuning function -Automatic learning of the motor’s characteristic curves
Test run with graphical evaluation of the motor currents/voltages
Up to 16 different characteristics of spindles can be stored
Very user-friendly debugging interface for setup control
Start/stop interface for cyclic permanent tests or remote control
Operating panel detachable and with extension cable to be used as remote control
Planned for the industrial use when drilling, grinding, milling. Swarf-proof housing
construction prevents the intrusion of impurity into the control electronics
Very compact form of housing allows the unproblematic installation into the
control cabinet
19” housing version for 3HE standard racks
Custom housings on request
User-friendly plug-in system for power and control connections
Wide range of mains voltage 115 V – 230 V
Plug connectors with screw elements
Automatic decelaration of the spindle after emergency stop or mains failure
Illuminated amber plain text display
Rotary encoder without mechanical catch for rotation speed control and menu control
Very user friendly operating menu in plain text
Temperature controlled fan
Different models
USB connection
Fully functional even without operating panel
Direct RS232 connection with adapter cable
5

SFU 0303
2. Description and Features
Operation of AC and DC motors
The high frequency converter SFU-0303 allows for rotation frequencies in AC motors of up
to 500,000 rpm in a 2-pole motor and in DC motors of up to 60,000 rpm.
High output power (3.6 kV with 230 V / 2 kVA with 115 V) in a compact design.
The core of SFU-0303 is a digital signal processor (DSP) which produces all output parameters
and collects signals.
All parameters like power, voltage and frequency are collected in real time and are regulated
by the implemented vector control depending on the load.
High-precision sinusoidal output signals with a low distortion factor and low deformation
allow for optimal rotation qualities in AC motors of all operating conditions.
Allows the highest efficiency of motors with low and with high frequencies.
High operating safety: All operating conditions like acceleration, operation with nominal
rotation speed, braking are controlled and critical conditions are intercepted. This includes
also the controlled braking of the motor / spindle in the case of a power failure or of an
emergency OFF.
Integrated braking resistance (optional). If no breaking resistance is integrated, the braking
times can extend to idleness.
Transparency: The user is always informed on the current status of the converter and the
spindle / motor in the plain text on a 3-line pluggable display on the front panel.
Control: The converter can be controlled and parameterised manually with a pluggable front
operating unit if the need arises.
6

Individual adjustment to the current application and the connected spindle. Up to 16
different characteristic lines of the spindle can be produced individually and be stored in the
converter, or existing lines can be modified and adjusted to the application.
A variety of control and communication options: There are 3 connections for the
communication with peripheral devices:
PC, PLC (programmable logic controller), CNC (computer numeric control).
Easy and flexible integration into existing equipments through free configuration of I/O
signals for control and configuration:
Control inputs: 2 analogue, 6 digital
Control outputs: 2 analogue, 6 digital (relays)
Galvanic separation of all interfaces from each other and from the mains / motor potential
Short circuit test
Easy configuration and control with the help of an optional PC Windows software
Automatic calibration of the spindle's characteristic curve
7

SFU 0303
3. Specifications of Device
Basic system SFU 0303
marking of different versions:
Examples:
8
Brake Resistor / Chopper: 0= without; 1= 220R; 2= 10R;
Adjustable Intermediate Circuit: 0= without; 1= with
Operating Panel: 0= without; 1= with
Housing: SSE = cabinet mounting; 19“ = rack mounting
T = desktop casing; S= special model
SFU 0303 SSE112 SSE with operating panel and adjustable intermediate circuit, 10R brake resistor
SFU 0303 SSE102 SSE with operating panel and no adjustable intermediate circuit, 10R brake resistor
SFU 0303 SSE100 SSE with operating panel and no adjustable intermediate circuit, no brake resistor
SFU 0303 SSE000 SSE without operating panel and no adjustable intermediate circuit, no brake resistor

4. Block Diagram
9

SFU 0303
5. Technical Data
Mains connection 115V, 60Hz, 1PH 230V, 50Hz, 1PH
Output power 2 kVA 3,6 kVA
5kVA at 20A industrial networks
Motor connection 10-poles: L1, N, 3*PE,U,V,W, PTC, FP, SGND Screw clamps 4mm2 Output voltage 3* 115V 3* 230V
Output current electronically limited
Over-current period can be regulated
Output frequency
Characteristic lines
AC: 8.8kHz / 500,000 rpm DC: 60,000 rpm
Of spindle max. 16, internally stored
Spindle sensor inputs PTC, magneto-resistor, logic 9 pluggable screw terminals
Control inputs 2 analog: 0-10V, galvanically separated: 10 pluggable screw terminals
Control inputs 6 digital: 0-24V, galvanically separated: 10 pluggable screw terminals
outputs 2 analog: 0-10V, galvanically separated: 10 pluggable screw terminals
Control outputs 6 digital: relay outputs, 12 pluggable screw terminals
24VDC/1000mA, 125VAC/500mA
Interface USB, RS232, RS485, profibus D-Sub 9 pole pins
Housing dimensions B 110 mm / H 275 mm / D 185 mm
Weight approx. 4 kg
Protection IP20
Operating temperature 40°C
10

6. Safety and Caution Instructions
This device produces dangerous electrical voltages and is used for the operation of dangerously
rotating mechanical parts. For this reason, only professionally qualified and trained personnel
may work with this device and install it!
Any work on the device may only be executed when the mains voltage has been turned off.
Before the initial operation is carried out, it has to be made sure that the motor is firmly
installed and can’t make any uncontrolled movements.
Whenever working on the device, it has to be guaranteed that all of the safety regulations
that are nationally valid are adhered to.
Maintaining EMC (electromagnetic compatibility) limits is the responsibility of the
manufacturer of the machine or the device. The inputs and outputs of this device are
equipped with filters in order to increase interference immunity and to reduce emitted
interference. Thus, the operation in an industrial environment is basically possible.
The EMC of a machine or a device is influenced by all the connected components (motor,
cable, wiring…). Under certain circumstances, the connection of external filters may be
necessary in order to guarantee the adherence to the legal EMC regulations.
For the above-mentioned reasons, the installation may only be carried out by qualified
personnel.
CAUTION: The operation of a spindle/motor with the wrong characteristic
line can cause severe damage to the spindle/motor! Please make always
sure that the correct characteristic line is chosen!
11

SFU 0303
7. View of Front Panel
12

8. Connections, Plugs and Pin Assignments
Operating parameters and outputs:
The SFU-0303 collects all of the current important operating parameters and data. Of
these, up to 6 parameters may be displayed at the digital outputs as a message and up
to 2 analogue values (0-10V) may be emitted at the analog outputs.
Remote control and inputs:
There are 6 digital inputs (24V) and 6 analog inputs (0-10V) available for the remote
control of SFU-0303.
These assignments can be configurated freely. With the optional Windows PC software
“SFU-Terminal” (>8.), the above-mentioned assignments can be made easily. Thus, an
extremely flexible adjustment to the different applications is possible. Every operating
parameter as a message and every control signal can be assigned to any I/0-pin. Moreover,
the current logic level (high- or low-active) can be defined individually.
The same assignment is also possible for the analogue performance data and control
data to the analog I/0-pins.
The standard assignment of operating parameters and related outputs and control signals
and inputs is listed in the following chart.
13

SFU 0303
8.1 Digital and Analog Inputs X2 (10 pluggable screw terminals)
14
Pin Designation Direction Function / Message / Default Setting
1 digital in 1 input start
2 digital in 2 input Power stage pulse inhibitor
3 digital in 3 input output stage off
4 digital in 4 input interlock
5 digital in 5 input error reset
6 digital in 6 input direction of rotation
7 analog in 1 input duty value for rotational speed 10Vmin./max.
8 analog in 2 input duty value for vario load
9 GND reference ground for the signals
10 +24V/50mA output auxiliary supply
For customer-oriented adjustments, different assignments of the input
and output values may be valid. The assignment and the I/0 numbers
can be freely programmed with the help of the software.
Switch level digital inputs: 0...7V=Log "O"/18...24V=Log"1"
The "hi" level for the digital inputs 24 V (SPS standard level).
Analog input voltage range: 0...10V
The +24V at pin 10 may be used as an auxilary supply e.g. for an
electronic spindle interface.

8.2 Digital and Analog Outputs X3 (12 pluggable screw terminals)
Pin Designation Direction Function / Message / Default Setting
1 relay common common bar relay connections
2 relay 6 normally closed contact output feedback on pulse inhibitor 3
3 relay 5 normally closed contact output over-temperature converter or spindle
4 relay 4 normally closed contact output overload
5 relay 3 normally closed contact output standstill converter + spindle
6 relay 2 normally closed contact output
7 relay 2 normally open contact output spindle ready
8 relay 1 normally closed contact output
9 relay 1 normally open contact output converter ready
10 analogue out 1 output
11 analogue out 2 output
12 output magneto resistor output square signal of rotary encoder
X3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
9
For customer-specific adjustments, other assignments of the input
and output values may be valid. The assignment and the I/0 numbers
are freely programmable with the help of the software.
The digital outputs (relay 1…6) are electrically isolated (500V
isolation). DC: 24V / 1000mA; AC: 125V / 500mA
Output level hall sensor magneto resistor: 0-24V (24V level)
The GND for Pin 10,111, 12 is X2.9
15

SFU 0303
8.3 Spindle Interface X4 (9 pluggable screw terminals)
Pin Name Direction Function
1 +12V/50mA output auxiliary voltage
2 S/GND ground for spindle interface signals
3 NC Not connected
4 rotary encoder input input input for two-/three-wire magneto resistors
5 PTC input temperature signal of spindle
6 bit 4input automatic spindle recognition
7 bit 3 input automatic spindle recognition
8 bit 2 input automatic spindle recognition
9 bit 1 input automatic spindle recognition
3
2
For customer-specific adjustments, other assignments of the input
and output values may be valid.
1
Inputs for automatic spindle recognition can also be used for external
characteristic line switching of the spindle.
16
X4
9
8
7
6
5
4
3
2
1
The spindle interface is electrically isolated from all the other signals
via optocoupler. It may be used for automatic spindle recognition if
it is activated. The logic levels are in a default way LOW-active: Hi >
pin on spindle S/GND, Lo > pin open. In the menu “Digital Inputs”
this may be changed.
The input PTC is intended for the recognition of over-temperature at
the spindle. If the resistance between PTC and GND is > 600 ohm, the
error message "over-temperature spindle" is activated and a safety
cutoff is executed after an adjusted delay.
The input FP for the rotary encoder or the hall sensor respectively works
in the range of +/- 1V with a common mode range of 0..10V.
The +12V at pin 9 may be used as auxiliary voltage, e.g. for an active
magneto resistor.

8.4 Mains connection, Spindle Connection with
Plug Connectors
8.5 Screw Clamp Connectors
Auxiliary supply for active magneto resistor 12V/50mA
Ground for PTC, Mr
Rotary encoder spindle magneto resistor / hall sensor
Spindle PTC
Spindle phase W
Spindle phase V
Spindle phase
External braking resistance / chopper resistor
Intermediate circuit voltage
Protective Earth
Protective Earth
Neutral
Mains phase
CAUTION:
Use control cables, power lines
and motor cables separately.
Use shielded cables.
17

SFU 0303
8.6 RS 232, RS 485
Unscrew with 2.5mm Allen key
8.7 USB Connection
18
The connection to the PC via RS232
and RS 485 is made with previously
configurated BMR cables.
USB connecting cable see
point 20 "Accessories"
For connection and communication with a
PC it is implemented an USB interface on the
operating panel
USB Mini AB
(enlarged picture)

9. Description of Function, Setup, Operation
The series 0303 is equipped with a safe pulse inhibitor which must be operated
correspondinglyto use. To activate the output stage, you must connect a voltage of 24V to
the digital input 2. The feedback from the converter on the condition of the pulse inhibitor
is made, if existent, on the display of the control unit and on the digital output 6 of plug
X3. Without this adjustment, the device cannot be set up.
The power stage pulse inhibitor corresponds to the directives category 3 EN954-1/ for the
safety of actuators and in addition to that has a feedback on the condition via the output
relay 6, pin 2 bar X3.
Before the first use, it has to be guaranteed that the correct characteristic line is activated
for the connected motor. This is the case when the device with motor has been bought
from the producer as a system and when the necessary preadjustments have been stored.
In case of doubt, characteristic lines for all current spindle are available at BMR.
If a spindle with an unknown characteristic line is connected, it is easy to identify a
characteristic line with the help of the SFU Terminal software (-> point 10).
19

SFU 0303
9.1 Starting the Converter
There are several possibilities of starting the converter. It is generally valid that only the starter
itself can again also cause the order to stop, unless a higher-ranking emergency OFF or a safety
function causes the stop.
20
Start button at LCD control panel, rotation speed via rotary encoder
Exclusively digital control via the RS232/RS485/USB/profibus interface
Digital input together with an analog input for control of rotation speed. If no analog input
is enabled for the control of the rotation speed, the rotation speed is provided by the rotary
encoder at the control unit or via the RS232/RS485/USB/ profibus interface.
Requirement for the correct starting performance is a correctly activated, enabled pulse
inhibitor as well as the correct characteristic line for the connected motor.
If the control unit is plugged in, the status messages are made via the LCD display in plain
text. The status messages are always shown via the LED panel:

9.2 Status Informationen of LED Display
1 2 3
STATUS
4 5 6
LED 5: converter and
spindle ready
1 2 3
STATUS
4 5
1 2
6
LED 2, 4 and 5:
excess temperature
spindle
3
STATUS
4 5 6
LED 3: Emergency OFF
and/or interlock activated
1 2 3
STATUS
4 5 6
LED 2 and 5: converter
o.k., spindle working
1 2
STATUS
4 5
3
6
LED 1, 2, 4 and 5:
excess temperature
spindle + overload
1 2 3
STATUS
4 5 6
LED 6: pulse inhibitor
activated
1
STATUS
4 5 6
STATUS
4
2
LED 1, 2 and 5:
overload
3
1 2 3
5 6
LED 2 and 4:
excess temperature
converter
1 2 3
STATUS
4 5 6
LED 1, 3, 4 and 6:
earth connection
When the message “converter and spindle ready” appears, the start can be activated. Different
measures for trouble shooting are discussed in the appendix. The most common error source
is an emergency OFF which has not been handled, interlock or the pulse inhibitor. In these
cases, it is recommended to control the adjustments in the "digital starting" menu in the SFU
Terminal and to check if all releases are operated correctly.
21

SFU 0303
9.3 LCD Operating Panel
CAUTION: The operation of a spindle / a motor with an incorrect
characteristic line can lead to severe damages of the spindle / the motor!
Please make always sure that the correct characteristic line has been chosen!
If several spindles are operated simultaneously, it has to be safeguarded that they are
of the same type and that the correct characteristic line has been chosen for them!
Otherwise, this can lead to the damage of one or several spindles, as the operating
voltage of the spindles can vary extremely!
22
In the easiest case, the connected spindle is started with the START button. The set rotation
speed can be pre-selected with the rotary encoder and can be changed variably at any time
during the operation. For a correct start, the terms of points 9 and 9.1 “Setup and starting
performance” are valid.
All relevant system messages on rotation speed, load or troubles are made via the LCD
display on the operating unit.
The power released at the moment is shown in the lower part of the LCD as an analog bar
chart and as an absolute value in %. In the case of overload, this is also shown.
The pre-selected set rotation speed, the selected characteristic line of the spindle and the
momentary actual rotation speed of the spindle are shown.
In the case of a failure, the kind of error is shown in the text display.
Standstill ! 3
forw > 25000 rpm
Conv&Spin ready!
Characteristic line 3 of spindle
selected
Duty speed ok. 3
forw > 25000 rpm
-------------- 67%
Spindle rotates with set rotation
speed Power output 20%
Vorlage Englisch fehlt
3
Outp. 7830 rpm
-------- 67%
Converter accelerated
Power output 67%
Overload 3
Outp.> 25000
Conv. not ready
In the case of a failure, the kind of error is
shown in the plain text in the first line.
Vorlage Englisch fehlt

The following error displays are possible:
Pulse inh. act.! Error pulse inhibitor activated
Overload stop Error overload
Excess temp. conv. +spn Error excess temperature converter
Excess temp. spin. Error excess temperature spindle
Excess temp. conv. +spn Error excess temperature or spn. conv.
Overvolt. off! Error overvoltage off
Undervolt. off! Error undervoltage off
Undervolt. stop! Error undervoltage stop
Output st. off Error output stage switched off
Emergency Off act.! Error emergency OFF entry locked
Without spn. cable Error without spindle or cable break
RS232 error! Error timeout ser. interface
Char. line error:! Error characteristic line invalid!
Encoder error:! Error in the rotary encoder / hall sensor
Entry option:
Stop button Menu button Start button
integrated in
the rotary encoder
Normal display:
Line 1: Status
Line 2: Rotation speed / direction of rotation
Line 3: Load display %, progress bars
Green LED for start/run
Red LED for stop condition
Continued on page 24
23

SFU 0303
9.3 LCD Operating Panel
Adjustments:
Adjustment of rotation speed: turn left/right via rotary encoder. The set rotation speed is
always shown during the adjustment.
Start/stop: Via start/stop button. If the operating unit is removed during the start condition,
the converter automatically turns to stop condition.
Menu selection: Keep pushbutton in the rotary encoder pushed for more than 1 sec. The
following selection appears:
Direction of rotation Ri/le
Selection of char. lines Characteristic lines 1..16 are shown in the plain text
Debug mode Display of mains voltage/power and spindle voltage for 30s
Version info No. of current version and software date on line 2 for 5sec
Language German/English
Contrast Set contrast with rotary encoder ri/le
ESC Quitting the menu
With the rotary encoder, a menu item can be selected, the active entry is flashing. By pushing
the menu pushbutton, the final entry is selected. With ESC the menu is quitted without changes.
After approx. 10 sec without activity, the display returns to standard mode.
The adjustment of the direction of rotation and the selection of the characteristic line are only
possible during standstill.
Special function:
During the operation, the debug mode can
be switched on/off by briefly pushing the
menu button. The mains voltage, output
current and spindle voltage are displayed.
The display automatically returns to standard mode after approx. 30sec.
24
Mains: 318 V
Curr: 5,1 A
Spnd: 78 V

9.4 Adjustment of Rotation Speed
The preselection of the rotation speed can be made in two ways:
Manual preselection via the menu buttons
For this, the option button 0 in the line set rotation speed must be clicked on in the menu
“Analog Inputs” of the SFU Terminal software. Thus, all analog inputs are switched on
passive and no analog start signal is selected. The set rotation speed is shown on the LCD
display and can be altered with the rotary encoder the increase of the rotation speed
depends on the rotation speed of the rotary encoder. The rotation speed may also be altered
during the operation.
Preselection via analog input set rotation speed
For this, an analog input must be assigned to this function in the menu "Analog Inputs"
of the SFU Terminal software. In addition to that, a scaling must be made from rotation
speed to analog value in the corresponding edit field for set rotation speed (e.g.: 1V/10,000rpm
or 0-10V min/max).
The set rotation speed corresponding to the applied voltage and scaling is shown on the
LCD display and can be changed at will.
An input voltage of 0V leads to a standstill and the feed of a voltage >0V leads to the starting
or adjustment of a rotation speed corresponding to the selected scaling. For the above
mentioned scaling, a rotation speed of 40,000rpm is adjusted for e.g. 4V.
The selected adjustments must be written into the converter with the button
Only write parameters into the converter.
25

SFU 0303
9.5 Safety Functions
The below-mentioned adjustments of the menus refer to the SFU Terminal software.
The following incidents lead to a controlled braking according to the specified acceleration
data of the spindle, as they are established in the characteristic line for this spindle.
26
Stop because of excess temperature at the spindle, if this function is activated and if the
corresponding delay time (can be adjusted in the menu “Delays…excess temperature
spindle”) has been exceeded.
In the menu “Spindle”, this function can be activated with the check button Temp. Sensor,
and the delay time can be adjusted in the menu “Delays”.
Stop because of excess temperature of the converter after the corresponding delay time
has expired. Adjusted in the menu “Delays… excess temperature converter”.
Stop because of overload after expiration of the allowed delay time. The parameters for the
overload criteria are determined in the characteristic line. Normally, you take the power
value 100% for the S1 operation. About 10% more for the overload criterion, about 30%
more for the S6 operation, and as delay overload approx. 20sec.
Immediate stop because of exceedance of the maximal power of the converter.
Emergency stop via signal at the digital input Interlock.
Adjusted in the menu “Digital Inputs”.
The following incidents lead to a cut off of the output stage. The spindle is slowed down
only by its own load. Depending on the centrifugal mass, it can take a very long time until
the standstill has been reached. We recommend a rotary encoder in the spindle for a secure
recognition of the standstill.
Stop because of a short circuit at the spindle connection leads to a cut off of the output
stage. This is determined by internal limiting values for the maximal power of the converter.
Stop via signal at the digital input Output Stage Off. Adjusted in the menu “Digital Inputs”.
A re-start can only be made through a systematic stop/start sequency or through the feed
of a valid signal at the digital input Error Reset. Adjusted in the menu “Digital Inputs”. In
this case, the output stage is connected again after 4 sec.

9.6 Safe Pulse Inhibitor according to EN 954-1 K3
The SFU-0303 is equipped with a safe pulse inhibitor for power stage according to category 3.
The diagram shows a possibility of connection together with a PLC:
Safe pulse inhibitor according to EN 954-1category3:
For test purposes only, a bridge circuit can be added between terminal X2.2 and X2.10. Then
the converter is running, but it may not be used in equipments which must be certified
according to EN 954-1.
10. Profibus Connection
Safe pulse inhibitor according to
EN 954-1 category 3
Condition pulse inhibitor
activated, converter is in a safe
situation.
Level at terminal X3.2 for this
condition is “low”.
A profibus DP connection conforming to standards is available as an option.
The interface is integrated in the special version of the operating panel.
The adjustment of the profibus address is made via RS232 connection cable and SFU Terminal
Program.
The corresponding data plus command interpreter for the integration, e.g. into the S7 by
Siemens, can be found on the website in the download options under “BMR-GSD”.
It is always possible to make the adjustments with adapter cable and RS232 via the terminal
program.
27

SFU 0303
11. Setup, Configuration with Windows
Software
The SFU Terminal Software is a convenient tool for the configuration of frequency converters
of the series SFU 0102 up to SFU 0601. Moreover, it also offers the possibility of reading system
data and of parameterising them. For this purpose, the following steps should be taken:
1. Switch on the converter and make the connection via USB or the RS232.
2. Start the program SFUTerminal.EXE
The description is stored in the Help File, and can be found in the Manual
"SFU Terminal Software".
28

12. Automatic Calibration of Spindles and Adjustment
of the Corresponding Characteristic Curves
For this purpose, the converter is connected with a PC via USB or RS 232. The connection
can be made with an appropriate BMR RS232 cable or with a LCD operating panel with
USB connection. Now the software "SFU Terminal" may be started. At first, the data of the
converter are read out automatically.
Now choose "Tools" - "Automatic Diagram" in the menu bar.
CAUTION:
Damages to the motors or converters due to incorrect entries or incorrect
operations are outside of any warranty claims!
Continued on page 30
29

SFU 0303
12. Automatic Calibration of Spindles and Adjustment
of the Corresponding Characteristic Curves
Example 1, normal adjustment:
A 2-pole motor has a nominal voltage of 220V with a current of 5A with a maximal rotation
speed of 30,000 rpm at 30,000 rpm.
For the S1 operation, the nominal current is adjusted to 5A and the current limit for the
S6 operation is adjusted to 8A.
Example 2, field suppression:
A 2-pole motor has a nominal voltage of 220 V with a current of 5A with a maximal rotation
speed of 30,000 rpm at 20,000 rpm.
30
At first, only the characteristics of the motor must be entered. It is important that the correct
nominal voltage for the rotation speed is indicated. The reason for this is that motors can
also be operated in the field suppression, so that they can reach a higher rotation speed
than the actual nominated rotation speed. 12.000/sec should be adjusted as acceleration
values (Ramp up/down). It has to be safeguarded that the spindle can move freely on the
motor.
The automatic calibration is made by clicking on "Start Automatic". After a successful run,
store the characteristic curve and adopt it into the converter.

13. Examples of Connections
13.1 Logic and Safety Circuit
X2
X3
10
9
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
The spindle interface X4 is not wired here as the use depends very strongly on the configuration
of the spindle and on the different characteristic lines.
This interface should only be used in combination with the automatic spindle recognition
after prior consultation with BMR.
By assigning the four address lines, a characteristic line can be pre-selected in the spindle
via the SPS or external switches/plugs, as soon as this function has been enabled by the
SFU terminal software.
Continued on page 32
31

SFU 0303
13.1 Logic and Safety Circuit
13.2 Mains and
Spindle Connection
32
The digital feed can also be realized via outputs of programmable logic devices, with a
starting high level >20V. The chart shows a configuration with passive switches and the
internal voltage feed through the converter.
For stabilizing the analog standard of the rotation speed, a voltage regulator 78L10 is
recommended. In connection with a SPS, one usually takes a D/A converter output with
0-10V.
The outputs are executed in such a way that the logic levels 0V and +24V are generated by
the electrically isolated relays. For any other arrangement, the relay contacts can be wired
and used freely. In the arrangement shown above, the logic level is assigned to the GND
of the converter. The outputs shown in the diagram can be used directly as feed into a SPS.
Description of starting performance with enabled analogue input:
Enabling via input “dig. start”, the motor starts when the analog standard rotation speed
becomes higher than the minimal rotation speed (you can see this in the corresponding
spindle diagram in the area “min. rotation speed”) and continues when either input start
turns to low or when the standard rotation speed becomes lower than the minimum rotation
speed. If e.g. 10V is fed on analog input 1, the motor starts when the digital input 1 turns
to high. In this case, the motor accelerates to the maximal rotation speed.
Brake Resistor
Speed sensor

14. EMC
This device was developed for the operation in an industrial environment. For a troublefree
operation and in order to reduce the emitted interference, the following hints should
be observed when wiring:
The EMC of a machine or a device is influenced by all of the connected components (motor,
cable, wiring…). Under certain circumstances, the connection of external filters may be
necessary in order to guarantee the adherence to the legal EMC standards.
The earth and shield connections of all the devices used in interconnection with the converter
should be as short as possible and have as large a cross-section as possible.
Control units (SPS, CNC, IPC…) connected to the converter should be connected to a
common earth terminal bar.
Use serrated lock washers for the mechanical assembling in order to safeguard a good
electrical contact with the housing.
All connections to and from the converter should be made with shielded cables. Earth the
shield on both sides.
Power lines, motor lines and control lines should be laid separately on principle. When
crossings can’t be avoided, they should be executed at a 90° angle.
Lay the control wires as far away from the load wires as possible.
33

SFU 0303
15. Troubleshooting
Description of Error
When starting the SFU Terminal, the
converter isn’t found or the data
communication is defective:
The LCD display shows “Spindle not
ready”
34
Cause of Error, Corrective
The converter must be switched on.
Only original cables by BMR may be used.
USB cables shouldn’t be longer than 2m.
The cause is often an entry in the system
configuration of Windows. If the device manager
shows the Com Port No>12, it is recommended
to place the no. manually on the next free place
with the lowest no. (3 or 4…).
Check if the PTC in the spindle is defective or if
there is an excess temperature in the spindle.
Has the PTC been connected correctly (see Point
9. Example of Connection)?
Has the spindle been connected properly (see
Point 9. Example of Connection)?

Description of Error
The LCD display shows “Converter not
ready”
The spindle cannot be started via dig.
input, although “Converter” and
“Spindle” are ready:
Cause of Error, Corrective
Excess temperature converter may be activated
(if this is the case, check if the ventilator works
without fault).
The hardware current limiting has acted – actuate
error reset via Start, after release check if the
spindle has blocked, before you start again.
The general current limiting has acted, a new start
is possible after error reset (via Start or digital
pin).
A digital input “Interlock”, “Pulse inhibitor” or
“Emergency OFF” is still activated – check the
inputs.
An invalid characteristic line has been chosen –
check if the no. of the characteristic line
corresponds to the type of spindle.
When the magneto resistor is activated and the
MR-input shows failures (e.g. with an open input),
the spindle cannot be started – check the MRconnections.
When an analogue input has been activated
(Menu “Analogue Inputs”), the spindle will only
start with the analogue voltage corresponding to
the minimum rotation speed, if the digital input
for “Start” is activated at the same time. When the
green LED on the front panel flashes and the
spindle doesn’t rotate, maybe the motor cable
was drawn off after starting the converter.
Continued on page 36
35

SFU 0303
15. Troubleshooting
Description of Error
The display shows “Characteristic line
error xx”:
The message “Actual rotation speed
reached” disappears and “Set rotation
speed o.k.” appears with a higher
rotation speed. The message
"Encoder error" appears.
The message “Without spindle.., cable”
appears, although a spindle has been
connected:
36
Cause of Error, Corrective
An invalid characteristic line has been chosen, a
valid characteristic line can be chosen with the
control panel or with the SFU Terminal Software.
Restart with ESC or switching off/on of the
This is probably a failure of the rotary encoder.
There are either disturbances on the signal or the
signal level isn’t appropriate.
Check three phases and motor cable respectively.
Maybe a wrong characteristic line has been chosen.
The self test when starting takes as an inspection
value the adjustment of the adjusted spindle
diagram. If an inappropriate type of spindle has
been chosen, maybe the inspection current is too
low, and the spindle isn’t accepted.
Check characteristic line, type of spindle.
With an adjustment in the Terminal Software (box
“Spindle test” in the Terminal Software, main
form), this spindle test can be skipped. However,
this is not recommended if the spindle test is to
be used as a safety function.

16. Mechanics, Views, Dimensions
37

SFU 0303
17. EG Declaration of Conformity
38
Manufacturer: BMR GmbH
Unterreichenbacher Str. 1
90455 Nuernberg
Product: SFU 0303
The above mentioned products comply with the regulations of the following European
guidelines:
89/336/EWG approximation of legal regulations on EMC"
The adherence to the above mentioned guidelines requires an installation into the
total unit according to the EMC.
The following standards are applied:
EN 61800-3
C3 standards which are also complied with:
VDE 0839 Teil 6-4, IEC 61000-6-4
VDE 0160 Teil 100, IEC 61800-3
VDE 0847 Teil 4-8, IEC 61000-4-8
VDE 0847 Teil 5-5, IEC 61000-4-5
VDE 0875 Teil 11 + Bbl. 1, IEC / CISPR 11 (CISPR TR 28)
VDE 0847 Teil 4-6, IEC 61000-4-6
VDE 0847 Teil 4-2 +A1, IEC 61000-4-2 +A1
VDE 0847 Teil 4-11, IEC 61000-4-11
VDE 0847 Teil 4-3, IEC 61000-4-3 +A1
VDE 0839 Teil 6-2, IEC 61000-6-2
VDE 0847 Teil 4-4, IEC 61000-4-4
Nuernberg, April 12, 2008
Rudolf M. Brittling, executive director
Electric drives with variable rotation speed
EMC product standard including special
test procedures

18. General Hints
Our frequency converters are highly valuable precison devices. Please take care of
them with the necessary attention, to preserve their high precision, high power ability,
and long lifetime.
These devices leave our company only after a quality test and a load check have
been carried out. Before mounting and use please read the attached manual carefully and
pay attention to the points listed below.
Before the first activation of the device, verify if it is in a faultless optical condition.
If it was damaged during transportation, it must not be used and not turned on.
During the installation the safety regulations must be observed.
Before the converter is turned on for the first time, it should be verified that
connected parts cannot carry out uncontrolled movements.
The frequency converter must not be operated close to heating devices or
magnetic devices.
Sufficient air circulation around the converter should be ensured.
Fluids should be prevented from intruding into the housing.
If it seems to have happened, the converter has to be switched off immediately.
If the converter is connected to a remote control, it should be verified that the
switch is in the OFF position before connecting.
All repairs and maintenance on our converters must be carried out by skilled and instructed
persons, only.
All repairs and maintenance on the converter and the relating accessories must be carried
out by skilled and instructed persons in the OFF-state only. To ensure this, the mains plug
should be pulled out. In doing this, both the terms of regulations for preventing accidents
and the general and national rules for mounting and safety have to be applied.
Our common hints can give only a rough guideline because it is not possible for BMR
to deal with every specific situation. The compliance with the limits of EMC demanded
by law is the responsibility of the manufacturer of the unit or machine. By doing
controls and tests in our own laboratory, BMR can guarantee that our products comply
with the corresponding standards if they are installed and used in an appropriate
39

SFU 0303
19. Warranty
With exclusion of additional claims we give a warranty on our Frequency Converter for 1 year
on errors due to material, mounting and construction.
We commit to repair or replace the parts without any costs which seem to be
defective by our estimation and which are not damaged by not appropriate handling.
Warranty claims have to be sent to us in written form. The customer has to pay the costs to
send the defective device back to BMR within the time of warranty. If this is not complied with
or if we detect an external intrusion into our control unit, we withdraw our duty of warranty.
Our duty of warranty is limited to the repairing or replacing of the defective parts.
We refuse claims of responsibility or warranty for direct or indirect consequential
damages, caused by faults of our products.
Changes in construction may be carried out without any message or notification.
Our common terms of business conditions apply.
Subject to technical changes.
40
BMR GmbH is a dynamic and flexible company. We take into account specific
requirements of our customers as well as demanding solutions in design. These
are integrated according to qualitative and functional aspects maintaining of
course our high quality standard.
Our company is working according to the highest economical and ecological
standards which are mirrored at BMR in all areas. Especially in manufacturing
we try to improve our ecological standard constantly. It has been and is our
constant purpose to comply with these demands. Due to our constant efforts
we obtained in 1998 the certification according to DIN ISO 9001 for Quality
Management Systems.

20. Accessories
RS 232 P 2001.100012
USB-cable P 2001.100013
RS 485-cable P 2001.100014
Mounting bracket for the laying of cables + clamps P 1001.100006
Mounting brackets for housing A 1700.504133
Kit of clamps P 1001.100005
LCD-control unit P 1203.100003
41

42
The company BMR GmbH was founded in 1978.
We develop, construct and manufacture electronic devices
and electronic drive units.
Nearly all the steps of the manufacturing process are carried
out within our company.
The development department designs all our printed circuit
boards first in a schematic form and then as a layout. They
furthermore develop the firmware for the microcontrollers and
DSPs and even the Windows PC Software for our devices.
The manufacturing department solders and mounts
all the components. And finally in the quality and test
department the devices are tested and set up according
to the customers requirements.
We have established "short ways" between the departments in
order to guarantee a constant level of high quality and to be able
to realize changes fast and in a flexible way.
By keeping the manufacturing processes within our company,
we have gained years of knowledge and experience,
offering this further to our customers as an extra service.
Our goal is a quick,
flexible und reliable execution of orders.
With our long-time experience, especially in manufacturing
frequency converters, we have gained a strong position in the
market. This becomes evident especially in our
growing presence in domestic and overseas markets.

Our present
product profile:
High frequency converters for industrial use
Drive units for Electroluminescence displays
intelligent lighting controls
Control units for domestic appliances
Acoustic test units
Motor controls
Accumulator charger
Time controls, for example grease controls used in
automotive applications
Development of oem controls
Manufacturing of electronic devices using wire-through
and surface mount technique
We also work as an extended workbench for
well known companies
43

Our strength
is called quality!
The quality sign "Made in Germany" is the synonym for precision,
reliability and innovation.
BMR GmbH feels commited to these values. With two decades of
experience in the sector of developing, constructing and
manufacturing electronic devices and controls this was and still is
the prescription for our success.
Our policy of "short ways" ensures constant high quality. This makes
it possible to react rapidly, in time and flexible with changes and
requirements for our products.
This concept is valued by our customers and becomes evident in
our steadily growing presence in the market at home and abroad.
If you are interested in our products and accessories, contact us or
visit us on our website:
www.bmr-gmbh.de
BMR GmbH
Unterreichenbacher Strasse 1
90455 Nuernberg-Katzwang
Germany
Phone: .. +49(0)9122 / 63148-0
Fax:........+49(0)9122 / 63148-29
e-mail: info@bmr-gmbh.de
www.bmr-gmbh.de
Our Partner in the U.S.A.
HPT DRiVE SYSTEMS
HPT Precision Spindles & Drives Inc.
110 Newport Center Drive
Suite 200 Newport Beach, CA. 92660
USA
Tel. ............(001) (949) 719-1145
Fax:............(001) (949) 719-1150
e-mail: sales@hpt-drivesystems.com
www.hpt-drivesystems.com