Baumuller b maXX 5000 User guide

Application handbook
Language English
Original
Document No. 5.17002.02
Part No. 466346
Status 3-May-2018
E5.17002.02 Read the Instruction handbook before starting any work!
b maXX 5000
Servo pump 
function
Firmware-Version V1

Copyright These Application handbook may be copied by the owner in any quantity, but only for inter-
nal use. This Application 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 Application handbook are not per-
mitted.
Designations and company marks contained in these Application 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 follow-
ing applies:
this version is regarded as providing advance technical information to users of the de-
scribed 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
preliminary information.
Obligatory These Application handbook are a part of the equipment/machine. These Application 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 Application 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 de-
stroyed.
When the present Application handbook are handed over, corresponding sets of operating
instructions 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 Application handbook un-
less 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 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Guarantee conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.6 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Control Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Overview of operating pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Signal processing of set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Volume set values and pressure set values via field bus . . . . . . . . . . . . . . . . . . . . . 12
2.2.2 Volume set values and pressure set values via analogue inputs . . . . . . . . . . . . . . . 12
2.3 Signal processing of actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.1 Interface pressure actual values if add-on module SVP is available. . . . . . . . . . . . . 13
2.3.2 Interface pressure actual values if no add-on module SVP is available . . . . . . . . . . 13
2.4 Scaling and ramps of volume set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Ramps pressure set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Adaptation of the pressure controller parameters (kp, Tn) . . . . . . . . . . . . . . . . . . . . . 15
2.7 Speed stop at minimum pressure values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.8 Pump protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.9 Dataset switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Switching pressure sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.11 Maximum positive speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Reading in of pressure and volume set/actual values . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.1 Add-on module SVP as analog interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.2 Field bus combined with add-on module SVP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.3 Field bus combined with standard analog IO X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Add-on module SVP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.1 Connection pressure sensor with current interface. . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.2 Connection pressure sensor with voltage interface. . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Guided Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Commissioning set /actual values via fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Commissioning set /actual values via analog interface . . . . . . . . . . . . . . . . . . . . . . . . 45
4.4 Setting the pressure sensor inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1 Structure of the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Reserved bits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Revision Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Application handbook Servo pump function V1 for BM5000
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Table of Contents

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Application handbook Servo pump function V1 for BM5000
Document No.: 5.17002.02
1GENERAL INFORMATION
The application manual provides important information regarding handling the device. A
prerequisite for safe working is compliance with all specified safety information and han-
dling instructions.
Furthermore, the local accident prevention regulations and general safety requirements
applicable to the area of application of the device must be observed.
Before starting any work on the device, completely read through this Application hand-
book and the Instruction handbook of the device, in particular the chapter on safety infor-
mation. The handbooks are an integral part of the product and must be kept in the
immediate vicinity of the device in order to be accessible to personnel at all times.
For commissioning of the device the parameter manual must be used. The parameter
manual contains information to the parameters of the device.
NOTE!
The servo pump is only available for:
mSingle axis BM53XX
mMono units BM55XX
The following versions (or newer) are required:
mFirmware version 1.10
mProDrive version 1.17.1.11
mSoftDrivePLC Project „SdSP_100100_FW10_00_WT00“
NOTE!
The function servo pump has to be ordered in advance because an afterwards up-
grade is not possible.
The drive add-on servo pump-EX3 is mandatory for using servo pump software.

Explanation of symbols
Application handbook Servo pump function V1 for BM5000
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1.1
1.1 Explanation of symbols
Warnings Warnings are identified by symbols in this Parameter Manual. The notices are introduced
by signal words which express the magnitude of the danger.
Observe the notices without exception and exercise caution to prevent accidents, person-
al injury and damage to property.
Recommen-
dations
DANGER!
....warns of an imminently dangerous situation which will result in death or serious in-
jury if not avoided.
WARNING!
....warns of a potentially dangerous situation which may result in death or serious in-
jury if not avoided.
CAUTION!
....warns of a potentially dangerous situation which may result in minor or slight injury
if not avoided.
NOTICE!
....warns of a potentially dangerous situation which may result in material damage if
not avoided.
NOTE!
....points out useful tips and recommendations, as well as information for efficient,
trouble-free operation.

General Information
Application handbook Servo pump function V1 for BM5000
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1
1.2 Limitation of liability
All specifications and information have been compiled taking account of the applicable
standards and regulations, the state of the art and also our many years of expertise and
experience.
The manufacturer accepts no liability for damage resulting from:
mNon-compliance with the Instruction handbook
mNon-intended use
mUse of untrained personnel
The product actually supplied may deviate from the versions and illustrations described
here in the case of special versions, the use of additional ordering add-ons or as a result
of the latest technical changes.
The user is responsible for carrying out servicing and maintenance in accordance with the
safety regulations in the applicable standards and all other relevant national or local reg-
ulations concerning conductor dimensioning and protection, grounding, isolation switch-
es, overcurrent protection, etc.
The person who carried out the assembly or installation is liable for damage arising during
assembly or upon connection.
1.3 Copyright
b maXX®is a registered trademark of Baumüller Nürnberg GmbH, 
90482 Nürnberg, Germany
Treat the Application handbook confidentially. It is intended exclusively for persons in-
volved with the device. It must not be made available to third parties without the written
permission of the manufacturer.
NOTE!
The details, text, drawings, pictures and other illustrations contained within are copy-
right protected and are subject to industrial property rights. Any improper exploitation
is liable to prosecution.
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.

Guarantee conditions
Application handbook Servo pump function V1 for BM5000
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1.4
1.4 Guarantee conditions
The guarantee conditions are located as a separate document in the sales documents.
Operation of the devices described here in accordance with the stated methods/ proce-
dures / requirements is permissible. Anything else, e.g. even the operation of devices in
installed positions that are not shown here, is not permissible and must be checked with
the factory in each individual case. If the devices are operated differently than described
here, any guarantee will be invalidated.
1.5 Customer service
Our customer service department is available for technical information.
Information concerning the responsible contact person can be obtained at any time by
telephone, fax, e-mail or over the internet.
1.6 Other applicable documents
Instruction 
handbook
Parameter manual
Doc.-No. Part No.
German
Part No.
English
Instruction handbook b maXX 5000 5.09021 439682 439683
Instruction handbook b maXX 5500 5.13008 446683 446684
Doc.-No. Part No.
German
Part No.
English
Parameter manual b maXX 5000 5.09022 428331 431082

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Application handbook Servo pump function V1 for BM5000
Document No.: 5.17002.02
2CONTROL STRUCTURES
This chapter describes the structure of the servo pump function in the b maXX controller.
The control model is described by using graphics.

Overview of operating pages
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2.1
2.1 Overview of operating pages
Servo pump functionalities can be set in ProDrive:
Figure 1: Servo pump V1: General
Figure 2: Servo pump V1: Adaption

Control Structures
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2
Figure 3: Servo pump V1: Set/actual values
Figure 4: Servo pump V1: Pump protection

Signal processing of set values
Application handbook Servo pump function V1 for BM5000
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2.2
2.2 Signal processing of set values
2.2.1 Volume set values and pressure set values via field bus
Pressure
set value
P177.120
Qset
filtered
P177.35
Scaling
Pset
mBar
P177.020
P177.6
P177.7
Bar
Volt
Sca
l
in
g
P
se
t
m
B
a
r
P177.
0
2
0
P177.
6
P
1
77
.7
Bar
Volt
P 177.020 in mBar
Qset
ml/min
P177.042
P177.8 [ccm / U]
1
Q
set
ml
/
min
P177.
0
4
2
P177.8
[
ccm
/
U
]
1
P 177.042 in ml/min
Field bus
Field bus
Interface
overlaid control
Pmax = P177.6 =100%
Ramp down time
pressure set
P177.207
ms
Ramp up time
pressure set
P177.206
ms
Pressure set
value
Volume set
value
Scaling
Figure 5: Set values via field bus
2.2.2 Volume set values and pressure set values via analogue inputs
Offset Sca-
ling
Offse
t
Sca
-
l
ing
Add-on module SVP analog input 2
P176.64 P176.65P176.63
Offset Scal-
ing
Qset
filtered
P177.35
Offse
t
Sca
l
-
i
n
g
Add-on module SVP analog input 1
P176.61 P176.62
P176.60
Qset
filtered
P177.134
Pressure set
value
Interface
overlaid control
Volume set
value
0-10 V
or
0/4-20
mA
0-10 V
or
0/4-20
mA
Pressure
set value
Pmax = P177.6 =100%
Ramp down time
pressure set
P177.207
ms
Ramp up time
pressure set
P177.206
ms
Figure 6: Set values via analog inputs

Control Structures
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2
2.3 Signal processing of actual values
2.3.1 Interface pressure actual values if add-on module SVP is available
Offset Sca-
ling
P_actual
sensor 1
P177.175
Offse
t
Sca
-
l
ing
Add-on module SVP analog input 3
P176.67 P176.68P176.66
Pressure actual
value sensor 1
0-10 V
or
0/4-20
mA
Interface
pressure sensor
Offset Sca-
ling
P177.176
Offse
t
Sca
-
l
in
g
Add-on module SVP analog input 4
P176.70 P176.71P176.69
0-10 V
or
0/4-20
mA
Pressure actual
value sensor 2
P_act
P177.119
P_actual
sensor 2
IF P177.3
Bit 7 =
TRUE
Figure 7: Pressure actual values via add-on module SVP
2.3.2 Interface pressure actual values if no add-on module SVP is available
Pressure actual
value sensor 1 Offset Sca-
ling
Thre-
shold
P144.1 P144.2
P144.4
P144.3
Offse
t
Sca
-
l
ing
Thr
e
-
s
h
o
l
d
P
1
44
.1
P144
.2
P
1
44
.4
P
144.
3
Standard IO analogue input 1
Interface
pressure sensor
0-10 V
Offset Sca-
ling
Thre-
shold
P144.10 P144.11
P144.13
P144.12
Offse
t
Sca
-
l
ing
Thr
e
-
s
h
o
l
d
P144.1
0
P
1
44
.11
P
144.1
3
P144
.
1
2
Standard IO analog input 2
0-10 V
Pressure actual
value sensor 2
P_actual
Sensor 1
P177.175
P_act
P177.119
P_actual
Sensor 2
IF P177.3
Bit 7 =
TRUE
P177.176
Figure 8: Pressure actual values without using an add-on module SVP

Scaling and ramps of volume set values
Application handbook Servo pump function V1 for BM5000
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2.4
2.4 Scaling and ramps of volume set values
This scaling defines the scaling-relationship between the voltage-value of the Q-Set fil-
tered (ZP177.35–) in respect to the output drive-speed (nSet). The nSet-value is then
sent to the ramp function generator (see ZRamps pressure set values– on page 14).
Figure 9: Scaling and ramps of volume set values
2.5 Ramps pressure set values
The Ramp function generator (RFG) generates a function with rising and falling ramps.
The ramp up time can be defined in ZP177.206–and sets the time needed to raise the
pressure value to the pressure maximum value (ZP177.6–). The ramp down time can be
defined in ZP177.207–and defines the time for the pressure falling down from 100 % to
0 %.
Figure 10: Pressure ramp-up and ramp-down time
Pmax = P177.6 =100%
Ramp down time
Pressure set value
P177.207
ms
Ramp up time
Pressure set value
P177.206
ms
Pressure set value
P177.120
Pressure set value
Analog or field bus
Pressure ramp function generator

Control Structures
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2
2.6 Adaptation of the pressure controller parameters (kp, Tn)
Depending on control differences the pressure controller parameters can be dynamically
changed during the operating time.
Figure 11: Adaptation of the pressure controller parameters
Enter the control differences for which there should be a change in the pressure control
parameters. 
The control differences must be entered in ascending order. If entered incorrectly, all pa-
rameters are set to 1111..4444 and have to be re-entered.
The other parameters assigned to the control differences such as kp or Tn can be en-
tered.
It is possible to activate an interpolation between the values in order to provide a contin-
uous adaptive function between all entered values. 
Enable this function with bit 5 = 1 in ZP177.3–.
The filter order pressure controller adaption can be set to smooth the control deviation via
ZP177.205–.
Figure 12: Activation of interpolation
Pressure
Adaptation
P177.194
Control difference
threshold parameter
Pressure
controller
Pressure
Controller
P177.3
Bit 0 = 1
Adaption
ON
n Addition
set value
P Set
+
_
P Actual
P177.193
P177.192
P177.191
P177.196
P177.197
P177.198
P177.199
P177.195
P177.201
P177.202
P177.203
P177.204
P177.200
Kp
Tn
kp
Proportional
amplification
Tn
Integral
action time
P177.122
P177.62
P177.3
Bit 5 = 1
Interpolation
ON
Interpolation
Filter
Order P177.205

Speed stop at minimum pressure values
Application handbook Servo pump function V1 for BM5000
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2.7
2.7 Speed stop at minimum pressure values
If pressure actual value (ZP177.119–) is smaller than P actual value minimum
(ZP177.145–) and pressure set value (ZP177.120–) is smaller than P set value minimum
(ZP177.144–) speed limitations are set to 0. As a result in this low pressure area neither
volume nor pressure controller are active.
The speed limitation is suspended, if the pressure set value is greater than P Set value
minimum.
Figure 13: Speed stop at minimum pressure values
„P set value minimum“ and „P actual value minimum“ set pressure values stop the drive
if actual values are falling below this threshold value
This function prevents the drive from drifting slowly during the pressure control procedure
in the event of small set and actual pressure values.
The limit does not take effect until both (AND) limits have been underrun.
By setting the default values typical values were already entered.
The function is only activated in the pressure control system.

Control Structures
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2
2.8 Pump protection
The pump protection functionality recognizes a missing oil flow or wrong rotating direction
of the pump. If speed is greater than N/Q recognition threshold (ZP177.167–), pressure
actual value exceeds P actual value threshold (ZP177.168–). If P actual is lower than the
threshold drive error 1202 pump protection is generated.
Figure 14: Pump protection
2.9 Dataset switching
Servo pump software V1 of BM5000 supports an online (drive enabled) switching of up
to seven datasets. You can only switch to a valid dataset.
Figure 15: Dataset switching
The servo pump software V1 provides the parameter „Active Data Set“(ZP177.228–,
UINT) for switching drive datasets. This parameter can be written cyclically via field bus.

Switching pressure sensors
Application handbook Servo pump function V1 for BM5000
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2.10
2.10 Switching pressure sensors
The servo pump software of the BM5000 has the functionality to switch between two pres-
sure sensors for pressure control. 
If the used sensors have different pressure ranges, also scaling parameters must be
adapted (dataset switch recommended).
Bit 7 in Control word 1 (ZP177.3–)
mFalse: Pressure control using sensor 2
mTrue: Pressure control using sensor 1
The default used pressure sensor has to be connected to analog input 4 of add-on mod-
ule SVP or analog input 2 of standard module X6.
A second pressure sensor has to be connected at analog input 3 of add-on module SVP
or analog input 1 of standard module X6.
2.11 Maximum positive speed
If the value is set to 0 rpm, the pump only rotates in an anticlockwise direction.
For quicker depressurization it may be necessary for the pump to rotate briefly in the other
(clockwise) direction.
The maximum permissible (clockwise) speed must be calculated based on the pump
manufacturer's documentation.

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Application handbook Servo pump function V1 for BM5000
Document No.: 5.17002.02
3INSTALLATION
This chapter describes the servo pump-specific controller connections. This is applicable,
in particular, to the set and actual value sources.
For the connection of the b maXX 5000 device and the remaining control connections,
see Instruction handbook b maXX 5000, 5.09022 or b maXX 5500, 5.13008.
3.1 General information
In general there are different possibilities for reading in the set values for pressure and
volume and the actual value of pressure:
mAnalog
mField bus with add-on module SVP
mField bus with standard module X6
Furthermore a subdivision can be done depending on the signal form of analog signals.
In this chapter the different possibilities are described in detail.
WARNING!
All notes and in particular safety notes of the Instruction handbook b maXX 5000 or
b maXX 5500 must be considered.
NOTICE!
It is important to ensure that the pump in every operating point is operated within its
specifications. The limitation values for minimal-pressure, pressure-acceleration and
the characteristic-lines for pressure and speed can be found in the technical docu-
mentation of the pump-manufacturer.

Reading in of pressure and volume set/actual values
Application handbook Servo pump function V1 for BM5000
Document No.: 5.17002.02 Baumüller Nürnberg GmbH
20
of 76
3.2
3.2 Reading in of pressure and volume set/actual values
It is possible to switch the interface using the bit numbers 8 and 9 in ZP177.3–according
to the following table:
ZP177.3–= XXXX XXXX XXXX XXXX
11 | Add-on module SVP as analog interface (see Zpage 20–)
01 | Field bus combined with add-on module SVP (see Zpage 22–)
10 | Field bus combined with standard analog IO X6 (see Zpage 24–)
3.2.1 Add-on module SVP as analog interface
In this case the volume set value is set using analog module SVP-001-00X in slot B of the
b maXX controller.
The set pressure value and actual value are also provided via analog module SVP-001-
00X in slot B of the b maXX controller.
The pressure actual value can be read in from 0/4 - 20 mA or 0 - 10 V.
Figure 16: SVP as analog interface
Pressure
sensor