Baumuller b maXX 5500 manual 

Instruction handbook
Read the Instruction handbook before starting any work!
Language English
Translation
Document No. 5.13008.10
Part No. 446684
Status 22-May-2019
b maXX 5500
BM5500
BM5600
BM5700
Basic Units/
Power Modules
with Servo Controller
E5.13008.10

Copyright These 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 these Instruction handbook are not per-
mitted.
Designations and company marks contained in these 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 incorrect 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 These Instruction handbook are a part of the equipment/machine. These Instruction hand-
book must be available to the operator at all times and must be in legible condition. If the
equipment/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 Protection 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.1 Dimensions BM551X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Dimensions BM552X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.3 Dimensions BM5X3X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.4 Dimensions BM5X4X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.5 Dimensions BM5X5X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.6 Dimensions BM5X6X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1.7 Dimensions BM5X7X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3 Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3.1 System types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3.3.2 Requirements to the energy supply / supply system. . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3.3 Motor requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3.4 Required environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3.5 Correction factors if the operating conditions are changed. . . . . . . . . . . . . . . . . . . . 54
3.3.5.1 Operating altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3.5.2 Environmental temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.5.3 Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.6 Coherence between rated current and peak current. . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.7 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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3.4 Electrical data basic units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.4.1 Electrical data BM55XX universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.4.1.1 Electrical data BM5X1X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.4.1.2 Electrical data BM5X2X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4.1.3 Electrical data BM553X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.4.1.4 Electrical data BM554X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4.1.5 Electrical data BM555X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.1.6 Electrical data BM556X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.1.7 Electrical data BM557X universal units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.4.2 Electrical data BM56XX acceleration units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4.2.1 Electrical data BM563X acceleration units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4.2.2 Electrical data BM564X acceleration units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.4.2.3 Electrical data BM565X acceleration units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.4.2.4 Electrical data BM566X acceleration units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4.3 Electrical data BM57XX continuous current unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.5 Electrical data power modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.5.1 Electrical data BM552X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.5.2 Electrical data BM553X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.5.3 Electrical data BM554X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.5.4 Electrical data BM555X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.5.5 Electrical data BM556X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.5.6 Electrical data BM557X power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.6 Additional data referring to water-cooled brake resistors. . . . . . . . . . . . . . . . . . . . . . 113
3.7 Output frequency dependent continuous current derating BM5XXX . . . . . . . . . . . . . 119
3.8 Output frequency dependent maximum current derating BM56XX . . . . . . . . . . . . . . 120
4 Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3 Type code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.3.1 Explanation type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.4 Display and operation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.4.1 7-segment display controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.4.2 LED display controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.4.3 LED display fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.4.4 Setting the IP address with address switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5 Transport and Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.1 Safety notes for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.2 What to observe when transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.3 Transport inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
5.5 Disposal of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
6.2 Preparing for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.1 Drilling patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
6.2.1.1 Drilling patterns BM551X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.2.1.2 Drilling patterns BM552X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.2.1.3 Drilling patterns BM553X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.2.1.4 Drilling patterns BM5X4X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.2.1.5 Drilling patterns BM5X5X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.2.1.6 Drilling patterns BM5X6X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.2.1.7 Drilling patterns BM5X7X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.3 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.3.1 Requirements mounting plate for cold plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.3.2 Connecting the water cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.2 Voltage test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.3 Demands on the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.4 Requirements to the connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.5 Protection of the device and the cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.6 PE connection and RCD compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.7 Installation requirements with regard to EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.8 Avoid bearing currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.9 Requirements for the motor temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.10 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.11 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.11.1 Connection diagrams without controller connections. . . . . . . . . . . . . . . . . . . . . . . . 171
7.11.1.1 BM55XX, BM56XX, BM57XX (basic units). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
7.11.1.2 BM55XX, BM56XX, BM57XX power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.11.1.3 Connection of several devices to the DC link without using the signal bus . . . . . . 177
7.11.2 Terminal overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.11.2.1 Terminals BM551X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.11.2.2 Terminals BM552X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7.11.2.3 Terminals BM553X, BM563X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.11.2.4 Terminals BM554X, BM564X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.11.2.5 Terminals BM555X, BM556X, BM565X, BM566X . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.11.2.6 Terminals BM566X, BM576X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.11.2.7 Terminals BM5755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.11.2.8 Terminals BM557X, BM5773 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7.11.3 Electrical connection power unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.11.4 Requirements for the screwing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.12 Controller terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.1 Operating concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8.1.1 Release signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8.2 Power on switching frequency / DC link charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
8.2.1 Power supply switch-on frequency BM551X and BM552X . . . . . . . . . . . . . . . . . . . 219
8.2.2 Power supply switch-on frequency BM5X3X to BM5X7X . . . . . . . . . . . . . . . . . . . . 219
8.2.3 Calculation of the maximum permitted external capacitance. . . . . . . . . . . . . . . . . . 220
8.2.4 Effects of the different charging circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.2.5 Table of charging times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.3 Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
8.4 Fieldbus communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
8.4.1 EtherCAT®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
8.4.2 VARAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
8.4.3 CANopen®.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
8.4.4 POWERLINK®.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
9.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
9.2 Environmental condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
9.3 Inspection intervals - maintenance notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
9.3.1 Periodic maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
9.4 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
10 Troubleshooting and fault correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.1 Behavior in case of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.2 Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.3 Fault detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
10.4 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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Table of Contents
11 Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
11.1 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.1.1 Cables power supply-device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.1.2 Cables device-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
11.1.3 Hybrid cable device-encoder-motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
11.1.4 Control voltage supply/signal cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11.1.5 Encoder cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11.1.5.1 Connecting cable for resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
11.1.5.2 Connecting cable for encoders with HIPERFACE®. . . . . . . . . . . . . . . . . . . . . . . . 259
11.1.5.3 Connecting cable for encoder with EnDat®or SSI. . . . . . . . . . . . . . . . . . . . . . . . . 260
11.1.5.4 Connecting cable for encoder with EnDat®2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
11.1.5.5 Connecting cable for sine/square-wave incremental encoder . . . . . . . . . . . . . . . . 263
11.1.5.6 Connection cable add-on modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
11.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
11.2.1 Fuses BM551X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
11.2.2 Fuses BM552X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
11.2.3 Fuses BM5X3X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.2.4 Fuses BM5X4X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
11.2.5 Fuses BM5X5X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
11.2.6 Fuses BM5X6X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
11.2.7 Fuses BM557X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
11.2.8 UL fuse in the ballast circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
11.2.9 24V extra-low voltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
11.3 Mains filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
11.3.1 Block diagram of filter for mains applications (simplified) . . . . . . . . . . . . . . . . . . . . 284
11.3.2 Baumüller mains filter type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
11.3.3 Required mains filter environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
11.3.4 Electrical data mains filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
11.3.5 Mains filter selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
11.4 Power chokes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
11.5 Baumüller accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
11.5.1 Shielding clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
11.5.2 Accessories Ethernet/EtherCAT®/VARAN/POWERLINK®. . . . . . . . . . . . . . . . . . . 292
11.5.3 Accessories - CANopen®. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
11.5.4 Service interface cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
11.5.5 Toroidal cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
11.5.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
12 Shutdown, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
12.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
12.2 Requirements to the executing personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
12.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
12.4 Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
12.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
12.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
13 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
13.1 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
13.2 Disposal facilities/authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Appenidx A - Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Appenidx B - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Overview of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

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Instruction handbook b maXX BM5500, BM5600, BM5700
Document No.: 5.13008.10
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
Recommendation
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.
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 Produkt 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
Procure spare parts through an authorized dealer or directly from the manufacturer. 
Refer to ZAccessories and Spare Parts– from page 245.
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 301.
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 in other mounted positions, is not permitted and must be cleared. 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 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 BM5500, BM5600, BM5700 are also used in
this documentation for this Baumüller product. A list of the abbreviations used can be
found in ZAppendix A - Abbreviations– from page 305.
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.