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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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.

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 5.15029 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 BM5500, BM5600, BM5700
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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 BM5500, BM5600, BM5700 are either mains rectifier or
active mains rectifier in combination with power modules with servo controller. Devices
are also available in graduated design size and performance classes.
The device BM5500, BM5600, BM5700 is used exclusively as a converter for controlling
a motor.
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.
mThe device has been developed in such a manner that it fulfills the requirements
of the category C3 according to IEC 61800-3:2012.
mThe device is not intended to be connected to the public power supply system. To
operate the device in primary surroundings of the category C2/C1 (residential,
business and commercial areas, directly on a public low-voltage power supply
without an intermediate transformer), special measures to reduce the transient
emissions (line-internal and radiated) must be provided for and certifiable by the
system builder. Otherwise, EMC interference could occur without such additional
measures.

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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2.5 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 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 Protection devices
Protection classification
BM5X1X, BM5X2X IP 20
BM5X3X, BM5X4X IP 20, with a contact-isolated con-
nection in accordance with IP 20,
otherwise IP 10.
BM5X5X, BM5X6X, BM5X7X IP 00
All devices BM5500, BM5600, BM5700 must be installed in an appropriate control cab-
inet to meet the protection classification required in EN 61800-5-1, chapter 4.2.3.3 (IP 30:
only upper horizontal surfaces; IP 20: all other surfaces).
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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2.8 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 basic units– ab Seite 61.
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.