Baumuller b maXX 5000 BM5800 Series manual 

Instruction handbook
Read the Instruction handbook before starting any work!
Language English
Translation
Document No. 5.16027.04
Part No. 464136
Edition 22-May-2019

b maXX 5000
BM5800
Multi-axis controller
E5.16027.04

Copyright This Instruction handbook may be copied by the owner in any quantity, but only for internal
use. This Instruction handbook may not be copied or reproduced, in whole or in part, for any
other purposes.
The use and disclosure of information contained in this Instruction handbook are not permit-
ted.
Designations and company marks contained in this Instruction handbook could be trade-
marks, the use of which by third parties for their own purposes could violate the rights of the
rights holder.
Preliminary information
Warning Insofar as this document is identified as being preliminary information, the following
applies:
this version is regarded as providing advance technical information to users of the described
devices and their functions at an early enough time in order to adapt to any possible changes
or expanded functionality. 
This information must be regarded as being preliminary, as it has not yet passed through
Baumüller's internal review process. In particular, this information is still subject to changes,
thus no legal liability can be derived from this preliminary information. Baumüller assumes no
liability for damages that might arise from this possibly faulty or incomplete version. 
If you detect or suspect any content errors and/or major form errors in this preliminary infor-
mation, we request that you notify the Baumüller support specialist responsible for you.
Please provide us, via this employee, with your insights and comments so that we can take
them into account and include them when transitioning from the preliminary information to
the final information (as reviewed by Baumüller). 
The conditions stipulated in the following section under „Obligatory“ are invalid in case of pre-
liminary information.
Obligatory This Instruction handbook are a part of the equipment/machine. This Instruction handbook
must be available to the operator at all times and must be in legible condition. If the equip-
ment/machine is sold or moved another location, these Instruction handbook must be passed
on by the owner together with the equipment/machine.
After any sale of the equipment/machine, this original and all copies must be handed over to
the buyer. After disposal or any other end use, this original and all copies must be destroyed.
When the present Instruction handbook are handed over, corresponding sets of instruction
handbooks of a previous version are automatically invalidated. 
Please note that the specifications/data/information are current values according to the
printing date. These statements are not legally binding with regard to measurements,
computation or calculations.
Baumüller Nürnberg GmbH reserves the right, in developing its products further, to change
the technical specifications and handling of it products concerned without prior notice.
No liability can be accepted concerning the correctness of these Instruction handbook unless
otherwise specified in the General Conditions of Sale and Delivery.
Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
90482 Nuremberg
Germany
Tel. [phone] - 0 
Fax: [phone] - 1 30
Email : [email protected]
Internet: www.baumueller.de

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Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information on the instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 List of other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Contents of the Instruction handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Usage for the intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Risk assessment according EU Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.12 Conduct in case of danger or accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.13 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1.1 BM5807-S dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.2 BM5807-A dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.1 Requirements for control voltage / 24 V power supply . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.2 Requirements for the motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.4 Correction values at changed operation conditions . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.4.1 Correction values for the output current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.4.2 Correction values DC link voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3.5 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.1 Double axis modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.2 Single axis modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.3 Output frequency-dependent current derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.4 Load cycle according EN61800-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Identification of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.1 Part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.3 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3 UL notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 Display and operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4.1 Minimum configuration BM58XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4.2 Maximum configuration BM58XX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4.2.1 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4.2.2 Option: LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4.2.3 Option: 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.4.3 LED display fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3 Transport inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Preparing for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2.1 Drilling pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3.1 Mounting with mounting rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.3.2 Mounting without mounting rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.3.3 Mounting of the DC link bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2 Voltage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.3 Demands on the electrical mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.4 Requirements for the connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.5 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.6 Grounding concept of MAR and side-by-side mounted system . . . . . . . . . . . . . . . . . . 76
7.7 Installation requirements with regard to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.8 Shielding plan side-by-side mounted system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.8.1 Shielding connection mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.8.2 Shielding connection with shield sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.8.2.1 Mounting shield sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.8.2.2 Connecting the shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.9 Requirements for the motor temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.10 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.11 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.11.1 Connection diagram overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.11.2 Connection diagram axis module -1 / -2 / -3 (single axis module). . . . . . . . . . . . . . . 87
7.11.3 Connection diagram axis module -1 / -2 / -3 (double axis module) . . . . . . . . . . . . . . 88
7.11.4 Connections BM5800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.11.5 Connection data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
7.11.6 Option: STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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7.11.7 Fast digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.11.8 Encoder evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.11.9 Motor temperature and motor brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.11.10 Option: Additional fast digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.11.11 Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.11.12 Option: Analog outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.1 STO function option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
8.1.1 Safety notes according function STO (Safe Torque Off) . . . . . . . . . . . . . . . . . . . . . 110
8.1.2 Safety levels and safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.1.3 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.1.4 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8.1.5 Examples for input wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.2 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.3 Fieldbus communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.3.1 EtherCAT® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.3.2 VARAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8.3.3 CANopen® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.3.4 POWERLINK®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9.1 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.2 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10 Troubleshooting and Fault correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.2 Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10.3 Error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10.4 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
11 Accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.1 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.1.1 Device - mains cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.1.2 Hybrid cable device-encoder-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.1.3 Control voltage supply/signal cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11.1.4 EtherCAT®,VARAN, POWERLINK®cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11.1.5 Accessories - CANopen®.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
11.1.6 Encoder cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
11.1.6.1 Connecting cable for Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
11.1.6.2 Connecting cable for encoder with HIPERFACE®. . . . . . . . . . . . . . . . . . . . . . . . . 147
11.1.6.3 Connecting cable for encoder with EnDat®or SSI . . . . . . . . . . . . . . . . . . . . . . . . . 148
11.1.6.4 Connecting cable for encoder with EnDat®2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.1.6.5 Connecting cable for sine/square-wave incremental encoder . . . . . . . . . . . . . . . . 151
11.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11.2.1 Plug connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11.2.2 Accessories kit shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
11.3 Connection rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

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Table of Contents
12 Shutdown, Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
12.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
12.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
12.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
12.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
13 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Appendix A - Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Appendix B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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Instruction handbook b maXX 5800
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1GENERAL
1.1 Information on the instruction handbook
These instruction handbook provides important information on handling the device. A pre-
requisite for safe work is compliance with all specified safety notes and procedural in-
structions.
Additionally, the valid accident prevention regulations and general safety regulations ap-
plicable to the scope of application the device must be complied with.
Read the instruction handbook, particularly the safety notes chapter, completely before
beginning any work on the device. The instruction handbook is part of the product and
must be kept accessible to personnel at all times in the immediate vicinity of the device.
1.2 Key to symbols
Warning notes
Warning notes are identified by symbols in these instruction handbook. The notes are in-
troduced by signal words that express the extent of the danger.
It is imperative that these notes be complied with and are conscientiously regarded in or-
der to prevent accidents, personal injury and material damage.
DANGER!
....points out an immediately dangerous situation that will lead to severe injuries or
death if not avoided.
WARNING!
....points out a potentially dangerous situation that could lead to severe injuries or
death if not avoided.

Limitation of liability
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1.3
Recommen-
dations
1.3 Limitation of liability
All specifications and notes in these instruction handbook were compiled taking into ac-
count the applicable standards and regulations, the state of the art and our knowledge
and experience of many years.
The manufacturer assumes no liability for damages due to:
mnon-compliance with the instruction handbook
musage for other than the intended purpose
musage by untrained personnel
The actual scope of delivery can vary in case of optional equipment, laying claim to addi-
tional order options, or on account of the latest technical changes to the explanations and
representations described herein.
The user bears the responsibility for performing service and initial operation in accor-
dance with the safety regulations of the applicable standards and all other relevant gov-
ernmental or local regulations concerning the dimensioning and protection of conductors,
grounding, disconnectors, overcurrent protection, etc.
The person who carried out the mounting or installation is liable for any damage incurred
when assembling or connecting the device.
CAUTION!
....points out a potentially dangerous situation that could lead to minor or slight inju-
ries if not avoided.
NOTICE!
....points out a potentially dangerous situation that could lead to material damage if
not avoided.
NOTE!
....highlights useful tips and recommendations, as well as information for efficient and
problem-free use.

General
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1
1.4 Copyright protection
CANopen®is a registered trademark of CAN in Automation e. V.
EnDat®is a registered trademark of Dr. Johannes Heidenhain GmbH,
83301 Traunreut, Germany
EtherCAT®is a registered trademark of Beckhoff Automation GmbH, 
33415 Verl, Germany
HIPERFACE®
HIPERFACE DSL®is a registered trademark of SICK STEGMANN GmbH, 
78166 Donaueschingen, Germany
PROFINETis a registered trademark of PROFIBUS International
speedtec®is a registered trademark of INTERCONTEC GmbH
94559 Niederwinkling, Germany
The instruction handbook must be treated confidentially. It is to be used exclusively by
personnel who work with the device. The consignment of the instruction handbook to third
persons without the written permission of the manufacturer is prohibited.
1.5 Other applicable documents
Components of other manufacturers are integrated into the device. For these purchased
parts, hazard assessments have been performed by the respective manufacturers. The
compliance of the design construction with the applicable European and national regula-
tions has been declared for the components by the respective manufacturers.
NOTE!
The specific contents, text, drawings, images and other representations are copy-
righted and subject to industrial property rights. Any prohibited usage is punishable
by law.
NOTE!
Please note, that BAUMÜLLER is not responsible to examine whether any (industrial
property) rights of third parties are infringed by the application-specific use of the
BAUMÜLLER products/components or the execution.

Spare parts
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1.6
1.6 Spare parts
mOnly use original spare parts of the manufacturer.
Procure spare parts through an authorized dealer or directly from the manufacturer.
Refer to ZAccessories and spare parts– from page 135.
1.7 Disposal
Insofar as no take-back or disposal agreement has been made, please disassemble units
correctly and properly recycle the constituent parts.
Refer to ZDisposal– on page 159.
1.8 Guarantee provisions
The guarantee provisions are stated in a separate document of the sales documents.
The devices described herein may only be operated in accordance with the stipulated
methods, procedures and conditions. Anything else not presented here, including the op-
eration of devices in mounted positions, is not permitted and must be cleared with the
plant on a case-by-case basis. If the devices are operated in any other manner than as
described within these instruction handbook, then all guarantee and warranty rights are
rendered null and void.
1.9 Customer service
Our customer service is available to provide you with technical information.
Info on the responsible contact persons is available at all times via telephone, fax, mail or
the Internet.
1.10 Terms used
The term „device“ or the item designation BM58XX are also used in this documentation
for the Baumüller product „b maXX 5800“. A list of the abbreviations used can be found
in ZAppendix A - Abbreviations– from page 163.
WARNING!
False or flawed spare parts can lead to damage, malfunction or complete fail-
ure, thus endangering safety.
Therefore:

General
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1
1.11 List of other applicable documents

Instruction 
handbook

Parameter manual
Instruction 
handbook safety
modules
Instruction 
handbook add-on
modules
Application
handbooks
Doc.-No. Part No.
German
Part No.
English
Instruction handbook b maXX 5000, 5100, 5300 5.09021 439682 439682
Instruction handbook b maXX 5500, 5600, 5700 5.13008 446683 446684
Instruction handbook b maXX 5800 5.16027 464134 464136
Doc.-No. Part No.
German
Part No.
English
Parameter manual b maXX 5000 5.09022 428331 431082
Parameter manual b maXX 5800 5.16029 470715 470716
Doc.-No. Part No.
German
Part No.
English
Safety modules for b maXX 5000 BM5-O-SAF-000/-001 5.09013 428339 432449
Safety modules for b maXX 5000 BM5-O-SAF-002/-003 5.01046 354843 372666
Doc.-No. Part No.
German
Part No.
English
Add-on module IEE / SIE 5.13030 448189 448190
Doc.-No. Part No.
German
Part No.
English
CANopen, CoE, POWERLINK for b maXX 2500/3000/5000 5.14006 450924 450925
SoE-Slave for b maXX 2500/3000/5000 5.14010 452983 452984
PROFINET IRT device for b maXX 2500/3000/5000 5.15009 456326 456327
Servo pump function V1 for b maXX 5000 5.17002 - 466346

List of other applicable documents
Instruction handbook b maXX 5800
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1.11

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

Usage for the intended purpose
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2.3
2.3 Usage for the intended purpose
The device is conceived and constructed exclusively for usage compliant with its intended
purpose described in these instruction handbook.
The devices of the model series b maXX 5000 are either mains rectifier or active mains
rectifier in combination with axis units or multi-axis controllers or decentralized drive solu-
tions. Devices are also available in graduated design size and performance classes.
The multi-axis controller b maXX 5800 is connected to mains rectifier or active mains rec-
tifier of b maXX 5000. The integrated axis modules are used for controlling motors.
A device is considered as being used compliant with its intended purpose if all notes and
information of these instruction handbook are adhered to.
WARNING!
Danger arising from usage for an unintended purpose!
Any usage that goes beyond the intended purpose and/or any non-compliant use of
the device can lead to dangerous situations.
Therefore:
mOnly use the device compliant with its intended purpose.
mObserve all specifications of these instruction handbook.
mEnsure that only qualified personnel work with/on this device.
mWhen configuring, ensure that the device is always operated within its specifica-
tions.
mMount the device on a wall that can sufficiently bear the load.
mThe device must always be operated within a control cabinet.
mEnsure that the power supply complies with the stipulated specifications.
mThe device may only be operated in a technically flawless condition.
mOnly operate the device in combination with components approved by Baumüller
Nürnberg GmbH.

Safety
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2
2.4 Risk assessment according EU Directive
Earth current Check the quality of the earth connection: 
- before connecting the device to the power supply for the first time and 
- within the recommended service intervals
Requirements:
mCross section of the grounding cable according EN 61800-5-1
mNote the required torque of connection!
mGrounded mounting plate made of metal
mMains filter, device and shielding of the motor cable are on the same HF potential
Stored 
electric charge
Do not touch electrically live parts before the discharge time of 15 min runs up, check
zero-potential before touching.
Electromagnetic
fields
The device causes electromagnetic fields when operating.
Any person with individual device for cardiac assistance (pacemaker, defibrillator) must
stay in sufficient distance to the operating device.
Burn injuries Please note that the surface of the device can heat up considerably.
mWear safety gloves!
Radiatedemission The high-frequency electromagnetic fields within the operation environment must not ex-
ceed the field strength of the second environment according EN 61800-3.
Internal or 
external 
ignition source
Internal or external ignition sources are not allowed within the environment of the devices!
mUse ABC powder for extinguishing a fire!
Gas Toxic fumes can be released in case of failure.
No flammable fume or dust and no flammable/explosive gases are permitted within the
environment of the devices!
In order to avoid damage to persons because of explosions:
mventilate the area and
mimmediate evacuation.
Transportation
and mounting
Falling down of the device can cause damage to persons.
Note the weight of the device when selecting the mounting screws!
Select the fastening torques of the mounting screws according the specification of the
screw manufacturer!
mWear safety helmets/shoes!

Risk assessment according EU Directive
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2.4
Mounting Unprotected hands can be injured at the sharp edges of the device.
mWear safety gloves!
Unprotected eyes can be injured by thrown up metal particles caused by drilling or making
cut-outs.
mWear safety glasses!
Short-circuit in
power cables
In case of a short-circuit high current flows. This current induces a magnetic field in cable
loops. The magnetic field can cause failures of the device.
To avoid additional damage in case of a short-circuit in power cables,
nThe connection between power supply and device or between device and motor
must be laid without loop.
Device
Motor cable or
Device
power connection Motor cable or
power connection
Figure 1: Wiring of the power cables
Installation If a shielded cable is connected unshielded and this causes failure of the device/danger
to persons, the system manufacturer is responsible for.
Brake resistor
connection
The dissipation of the heat loss of the external brake resistor must be ensured.
Communication
errors
Ensure that a failure of the device will cause no danger to persons.
The safety notes of all further chapters of this documentation need to be carefully ob-
served!

Safety
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2
2.5 Responsibility of the operating company
The device is used in commercial areas. Thus, the proprietor of the device is subject to
the legal work safety regulations.
Along with the notes on work safety in these instruction handbook, the safety, accident
prevention and environmental protection regulations valid for the area of application of
this device must be complied with. Whereby:
mThe operating company must inform himself about the applicable work health and safe-
ty regulations and ascertain, in a hazard assessment, any additional hazards that could
arise from the special working conditions in the use area of the device. These must
then be implemented in the form of instruction handbook for operation of the device.
mThese instruction handbook must be kept accessible to personnel working with the de-
vice at all times in the immediate vicinity of the device.
mThe specifications of the instruction handbook must be adhered to completely and
without exception.
mThe device may only be operated in a technically faultless and operationally safe con-
dition.
2.6 Protective devices
IP code
BM58XX IP 10
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted.
Therefore:
mThe device must be in operated inside of a control cabinet that provides protection
against direct contact of the devices and at least meets the requirements of
EN 61800-5-1, Chapter 4.2.3.3.

Training of the personnel
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2.7
2.7 Training of the personnel
In these instruction handbook, the following qualifications are stipulated for various areas
of activity:
mOperating personnel
nThe drive system may only be operated by persons who have been specially trained,
familiarized and authorized.
nTroubleshooting, maintenance, cleaning, maintenance and replacement may only
be performed by trained or familiarized personnel. These persons must be familiar
with the instruction handbook and act accordingly.
nInitial operation and familiarization may only be performed by qualified personnel.
mQualified personnel
nElectrical engineers authorized by Baumüller Nürnberg GmbH, and qualified electri-
cians of the customer or a third party who have learned to install and maintain
Baumüller drive systems and are authorized to ground and identify electrical power
circuits and devices in accordance with the safety engineering standards of the com-
pany.
nQualified personnel have had occupational training or instruction in accordance with
the respective locally applicable safety engineering standards for the upkeep and
use of appropriate safety equipment.
WARNING!
Risk of injury due to insufficient qualifications!
Improper handling can lead to significant personal injury and material damage.
Therefore:
mCertain activities can only be performed by the persons stated in the respective
chapters of these instruction handbook.

Safety
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2
2.8 Personal protective equipment
The wearing of personal protective equipment is required when working in order to mini-
mize health and safety risks.
mThe protective equipment necessary for each respective type of work shall always be
worn during work.
mThe personal safety signs present in each working area must be observed.
Wear for special
work.
Protective work clothing
should be snug-fitting work clothes, with low tearing resistance, narrow sleeves and
with no extending parts. It serves to primarily protect against...
No rings or chains should be worn.
Hard hat
to protect against falling down and flying around objects.
Safety shoes
to protect against heavy objects falling down.
Protective gloves
to protect hands against friction, abrasion, puncturing or more severe injuries, as well
as contact with hot objects.
Protective eye wear
to protect the eyes against flying around objects and sprayed liquids.

Special hazards
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2.9
2.9 Special hazards
In the following section, the remaining marginal risks will be stated that have been iden-
tified as a result of the hazard analysis.
Observe the safety notes listed here and the warning notes in the further chapters of this
Instruction handbook to reduce health risks and dangerous situations.
Electrical current
Danger from re-
sidual energy
DANGER!
Risk of fatal injury from electrical current!
There is an immediate risk of fatal injury if live electrical parts are contacted. Damage
to the insulation or individual components can be life-threatening.
Therefore:
mSwitch off the electrical power immediately in case of damage to the power supply
insulation.
mOnly allow work on the electrical system to be performed by qualified personnel.
mSwitch off the current when any kind of work is being performed on the electrical
system and ensure safety before switching on again.
DANGER!
Risk of fatal injury from electrical current!
Stored electric charge.
Discharge time of the rack system = discharge time of the device with the longest DC
link discharge time in the rack system.
Refer to ZElectrical data– from page 36.
Therefore:
mDo not touch electrically live parts before taking into account the discharge time of
the capacitors.
mPay attention to the corresponding notes on the device.
mIf additional capacitors are connected to the DC link, the DC link discharge can
take a much longer time. In this case, the necessary waiting period must itself be
determined or a measurement made as to whether the equipment is de-energized.
This discharge time must be posted, together with an IEC 60417-5036 (2002-10)
warning symbol, on a clearly visible location of the control cabinet.