Baumuller b maxx BM4400 User manual

Instruction Handbook
Read instruction handbook before beginning to work!
Language English
Translation
Document No. 5.01042.12
Part No. 354842
Status 14-Nov-2014
E5.01042.12
b maXX
BM4-F-ENC-XX
ENC-XX
Encoder module
BM4400, BM4400 ES
BM4600, BM4600 ES
BM4700, BM4700 ES

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, this 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 is 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 this 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

Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
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Table of Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Information on this Instruction Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Copyright protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Guarantee provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.9 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.10 Used terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.11 List of associated documentations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Contents of the Instruction Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Changes and modifications to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Use, compliant with intended purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Responsibility of the operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Training of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9 Behavior in hazardous situations or at accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.10 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Operation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Current consumption of encoder modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Information regarding maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Specification of encoder modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 BM4-F-ENC-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.1 Slots BM4-F-ENC-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.2 Type plate BM4-F-ENC-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2.3 Type code BM4-F-ENC-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.4 Danger areas BM4-F-ENC-XX for standard controller . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 ENC-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.3.1 Position ENC-XX in the ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.2 Type plate ENC-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.3.3 Type code ENC-XX in ES controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Display and operation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Transport inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
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Table of Contents
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Preparation of mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2 Requirements on the electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.3 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3.1 Connection BM4-F-ENC-XX standard controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3.2 Connection ENC-XX ES controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3.3 Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.3.4 Construction guidance connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8 Commissioning/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.2 Procedure of the test-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.1 Recognition of the encoder module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2.2 Further information on parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.3 Function test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.3 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10 Troubleshooting and fault correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.2 Fault detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.3 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.3.1 Error reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.3.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11 Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.1 Motor-side encoder connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.2 Connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
12 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Appendix A - Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
Document No.: 5.01042.12
1GENERAL
1.1 Information on this Instruction Handbook
The encoder module ENC-XX or BM4-F-ENC-XX can be operated in combination with a
b maXX 4000, only.
Therefore this Instruction handbook is an addition to the Instruction handbook of b maXX
BM4400, BM4400 ES, BM4600, BM4600 ES, BM4700, BM4700 ES (short b maXX 4000)
5.12008.
The basic prerequisite for safe working is compliance with all the safety and handling in-
structions stated in the instruction handbook b maXX 4000.
Additionally, the valid accident prevention regulations and general safety regulations ap-
plicable to the scope of application the device must be complied with.
Read this Instruction handbook and the Instruction handbook b maXX 4000, particularly
the safety notes chapter, completely before beginning any work on the device. This In-
struction handbook is part of the product and must be kept accessible to personnel at all
times in the immediate vicinity of the device.

Key to symbols
Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
Document No.: 5.01042.12 Baumüller Nürnberg GmbH
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1.2
1.2 Key to symbols
Warning notes
Warning notes are identified by symbols in this 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.
Recommen-
dations
DANGER!
....this indicates a hazardous situation which, if not avoided, will result in death or se-
rious injury.
WARNING!
....this indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION!
....this indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE!
....indicates a hazardous situation which, if not avoided, may cause material damage.
NOTE!
....highlights useful hints and recommendations, as well as information for the effi-
cient and trouble-free use.

General
Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
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1
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:
mnoncompliance 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.
1.4 Copyright protection
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.
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.
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®
SinCos®
is a registered trademark of SICK STEGMANN GmbH,
78166 Donaueschingen, Germany
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.

Other applicable documents
Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
Document No.: 5.01042.12 Baumüller Nürnberg GmbH
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1.5
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.
1.6 Spare parts
Procure spare parts through an authorized dealer or directly from the manufacturer.
1.7 Disposal
Insofar as no take-back or disposal agreement has been made, please disassemble units
correctly and properly recycle the constituent parts.
See also b maXX 4000 5.12008, chapter Disposal.
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 this Instruction handbook, then all guarantee and warranty rights are ren-
dered 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.
WARNING!
False or flawed spare parts can lead to damage, malfunction or complete fail-
ure, thus endangering safety.
Therefore:
mOnly use original spare parts of the manufacturer.

General
Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
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1
1.10 Used terms
The term function module or the designation ENC-XX or BM4-F-ENC-XX is also used in
this documentation for the Baumüller product „encoder module“. A list of the abbrevia-
tions used can be found in b maXX 4000 5.12008, Appendix A: Abbreviations.
1.11 List of associated documentations
Instruction
handbook
Parameter manual
Instruction hand-
book
function modules
Instruction hand-
book
option modules
Doc No. Part No.
German
Part No.
English
Instruction Handbook basic unit b maXX 4400, 4600, 4700 (ES) 5.12008 444495 444496
Doc No. Part No.
German
Part No.
English
Parameter manual basic unit b maXX 4400, 4600, 4700 (ES) 5.03039 376339 377548
Doc No. Part No.
German
Part No.
English
Analog I/O module BM4-F-AIO-XX or AIO-XX 5.01045 354844 372665
Digital I/O module BM4-F-DIO/FIO-XX or DIO/FIO-XX 5.01046 354843 372666
Encoder module BM4-F-ENC-XX or ENC-XX 5.01042 354842 372861
Incremental encoder emulation module BM4-F-IEE-XX or IEE-XX 5.02020 354858 376728
SSI encoder emulation module BM4-F-SIE-XX or SIE-XX 5.03056 377123 379049
Doc No. Part No.
German
Part No.
English
DISC-NT slave BM4-O-DNT-XX 5.03007 367670 -
CANopen slave BM4-O-CAN-03 5.02014 368692 368693
CANopen slave programming handbook for controller 5.02065 368694 372860
CANopen over EtherCAT programming handbook 5.07017 413208 432414
CANopen slave for b maXX PLC application handbook 5.03057 376486 376487
b maXX drive PLC 5.01051 366197 354845
b maXX drive PLC application handbook 5.02004 366198 372017
BM4-O-ETH-01, BM4-O-ETH-02, BM4-O-CAN-04 for b maXX PLC 5.03001 366202 372042
BM4-O-ETH-01, BM4-O-ETH-02, BM4-O-CAN-04 CANopen master for
bmaXX PLC application handbook
5.03002 366203 372043
CANsync master for b maXX PLC 5.02056 366199 372025
CANsync slave for b maXX 5.02064 366201 372041
CANsync for b maXX PLC application handbook 5.02066 366200 372039
IEI for b maXX PLC 5.02013 366204 372044
PROFIBUS-DP slave for b maXX 5.03040 376488 376489
PROFIBUS-DP slave for b maXX PLC application handbook 5.03058 376490 376491
PROFIBUS-DP slave for b maXX controller programming handbook 5.03045 376757 377294
SERCOS slave module BM4-O-SER-01 5.04012 380910 381069

List of associated documentations
Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
Document No.: 5.01042.12 Baumüller Nürnberg GmbH
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1.11
SERCOS slave module BM4-O-SER-01 parameter handbook 5.04013 381652 381653
EtherCAT slave module BM4-O-ECT-01/ECT-01 5.06003 394953 394954
Ethernet with EtherCAT master for b maXX drive PLC 5.07001 407996 407997
Ethernet with EtherCAT master for b maXX drive PLC application handbook 5.07002 407998 407999
Ethernet with EtherCAT for b maXX drive PLC 5.10018 433997
POWERLINK Controlled Node BM4-O-PLK-01/PLK-01 ES 5.12072 444497 444498
POWERLINK Controlled Node BM4-O-PLK-01 ES application handbook 5.13013 445131 445132
Doc No. Part No.
German
Part No.
English

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Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
Document No.: 5.01042.12
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 this Instruction Handbook and the Instruction Handbook of b maXX 4000
5.12008 before working with the device. This also applies if the person involved with this
kind of device or a similar one, or has been trained by the manufacturer.
2.2 Changes and modifications to the device
In order to prevent hazards and to ensure optimum performance, no changes, additions
or modifications may be undertaken on the device that have not been explicitly approved
by the manufacturer.

Use, compliant with intended purpose
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2.3
2.3 Use, compliant with intended purpose
The BM4-F-ENC-XX is used compliant with its intended purpose, if it is built-in/operated
within b maXX 4000 controller, only.
The Encoder module is considered as being used compliant with its intended purpose if
all notes and information of this Instruction handbook and the Instruction handbook
b maXX 4000 5.12008 are adhered to.
2.4 Responsibility of the operating company
The device will be used in commercial areas. Thus, the proprietor of the device is subject
to the legal work safety regulations.
Along with the notes on work safety in this Instruction handbook and the Instruction hand-
book b maXX 4000 5.12008, the safety, accident prevention and environmental protec-
tion 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 operating instructions for operation of the device.
mThis Instruction handbooks 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 handbooks must be adhered to completely and
without exception.
mThe device may only be operated in a technically faultless and operationally safe con-
dition.
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.
mNote all specifications of this Instruction handbook and the Instruction handbook
b maXX 4000 5.12008.
mEnsure that only qualified personnel work with/on this device.
mWhen configuring, ensure that the device is always operated within its specifica-
tions.
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
2.5 Training of the personnel
In this 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 this Instruction handbook.

Special hazards
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2.6
2.6 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
manual 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 system = discharge time of the device with the longest DC link
discharge time connected to the DC link.
See Instruction handbook b maXX 4000 5.12008, chapter Electrical Data.
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.

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

Safety equipment
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2.8
2.8 Safety equipment
2.9 Behavior in hazardous situations or at accidents
Preventive mea-
sures
mAlways be prepared for accidents or fire!
mKeep first-aid equipment (e.g. first-aid kits, blankets, etc.) and fire extinguishers readily
accessible.
mFamiliarize personnel with accident signalling systems, first aid equipment and life sav-
ing equipment.
And if something
does happen: re-
spond properly.
mStop operation of the device immediately with an EMERGENCY Stop.
mInitiate first aid measures.
mEvacuate persons from the danger zone.
mNotify the responsible persons of the site.
mAlarm medical personnel and/or the fire department.
mKeep access routes clear for rescue vehicles.
WARNING!
Risk of fatal injury due to non-functional safety equipment!
Safety equipment provides for the highest level of safety in a facility. Even if safety
equipment makes work processes more awkward, under no circumstances may they
be circumvented. Safety can only be ensured by intact safety equipment.
Therefore:
mBefore starting to work, check whether the safety equipment in good working order
and properly installed.

Safety
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2.10 Signs and labels
The following symbols and information signs are located in the working area. They refer
to the immediate vicinity in which they are affixed.
WARNING!
Risk of injury due to illegible symbols!
Over the course of time, stickers and symbols on the device can become dirty or oth-
erwise unrecognizable.
Therefore:
mMaintain all safety, warning and operating labels on the device in easily readable
condition.
Electrical voltage
Only qualified personnel may work in work areas that identified with this.
Unauthorized persons may not touch working materials marked correspondingly.
DANGER!
Risk of fatal injury from electrical current!
See ZDanger from residual energy– auf Seite 14.
CAUTION!
Risk of injury due to hot surface!
Therefore:
mWear protective gloves

Signs and labels
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2.10

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Instruction Handbook b maXX (BM4-F-)ENC-XX (Encoder module)
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3TECHNICAL DATA
3.1 Operation conditions
The operation conditions of b maXX 4000 are valid, see Instruction Handbook
b maXX 4000 5.12008.
Transport temperature range - 25 °C to + 70 °C
Transport climatic class
EN 60721-3-2
2 K 3
Storage temperature range - 25 °C to + 55 °C
Storage climatic class
EN 60721-3-1
1 K 4
NOTICE!
Normally, non-conductive pollution occurs. Conductive pollution is unacceptable.
Conductive pollution can lead to the destruction of the device. The customer is re-
sponsible for destructions, which were caused by pollution due to conductive materi-
als or components.

Current consumption of encoder modules
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3.2
3.2 Current consumption of encoder modules
Voltage -15 V +5,0 V +15 V
Module type
BM4-F-ENC-01 24 mA 32 mA
BM4-F-ENC-11 23 mA 34 mA
BM4-F-ENC-21 24 mA 32 mA
BM4-F-ENC-02 24 mA 16 mA 13 mA
BM4-F-ENC-12 24 mA 16 mA 13 mA
BM4-F-ENC-03 54 mA 9 mA
BM4-F-ENC-04 50 mA
BM4-F-ENC-05 60 mA
BM4-F-ENC-06 75 mA
BM4-F-ENC-07 60 mA
BM4-F-ENC-17 75 mA
BM4-F-ENC-27 70 mA
BM4-F-ENC-08 48 mA 32 mA 26 mA