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K.

Wirsching

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K. Wirsching

Training Agenda :
Day 1
Introduction to Baumuller Servo Motors.
Use of Baumuller Servo Motors in Different Applications.
Introduction to Bmaxx 44xx Series.
Bmaxx Power Units.
Bmaxx Controller Architecture.
Difference in Function Module & Option Module.
Introduction to Option Modules.
Bmaxx Drive Trouble shooting.
Introduction to Pro-Drive Software
Q/A Session.

Day 2
Introduction to Drives Different Modes of Operation.
Use of Control-word & Status Word in Drive.
Drive Operation via Control-Word & Status-Word.
Oscilloscope function in the Drive.
Hands on Bmaxx Servo Drive & Motor.
Q/A Session.

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b maXX 4400

be maXX

Basics
& Troubleshooting
b maXX 44xx

b like
motion control
automation
XX
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b maXX 4400, Agenda

Power units

Sizes
Technical specification
Connection details
Monitoring
Cooling variants

Controller

Technical specification
Connection details
Function modules
Option modules

Troubleshooting

ProDrive

- Program Upload and Download

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Structure of b maXX 4000

Unit
cover

Controller
Power

cartridge

section
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b maXX 4400

bMaXX 44xx
Power Unit

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b maXX 4400 Basic unit


b) Type key Position and Description

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b maXX 4400, Technical specifications

Frequency:

47/63 Hz connection

Nominal connection voltage:

400 V

DC link Voltage :

540 V DC nominal voltage

Clock frequency:

4/8 kHz

Operating temperature range:

0 40C (to 55C by current derating)


32F 104F (to 131F by current derating)

Output voltage :

0 bis 95 % der connection voltage

Electronic supply:

external 24 V DC > diagnosis ability

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b maXX 4400, Power units, Size 1 + 2

Size 1: Size 1 S
Size
1S 1B

Size
2

Size 1 B

Size

IaN

Imax

Typ. Motor Power

Overload fact.

4412

2,5 A

5,0 A

1,1 kW

4413

4,5 A

9,0 A

2,0 kW

4414

5,5 A

20 A

2,3 kW

3,6

4414

7,5 A

20 A

3,4 kW

2,6

Size 2:
Size

IaN

Imax

Typ. Motor Power

Overload fact.

4422

7,5 A

15 A

3,4 kW

4423

11 A

22 A

5,0 kW

4424

15 A

30 A

6,8 kW

4425

15 A

40 A

6,8 kW

2,6

4426

22,5 A

45 A

10 kW

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b maXX 4400, Power units, Size 1 + 2

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b maXX 4400, Connections, b maxx 441x

backside

Size 1:
Power connection on top

frontside
frontside

+ 24 V
Output brake +
Output brake M 24 V
motor temperature sensor +
motor temperature sensor -

Motor connection on bottom

backside

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b maXX 4400, Connections, b maxx 442x

backside

Size 2:

frontside

Power connection on top

frontside

+ 24 V
Output brake +
Output brake M 24 V
motor temperature sensor +
motor temperature sensor -

Motor connection on bottom

backside

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b maXX 4400, Power unit, Size 3 - 7

Size
4432
4433
4434
4435
4442
4443
4444

Size 3 Size 4

Size 5

Size 6

Size 7

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4452
4453
4454
4462
4463
4472
4473

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b maXX 4400, Power units, Size > 3

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b maXX 4400, Power units, Size > 4

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b maXX 4400, Connections, b maxx 443x and b maxx 444x

backside

frontside

+ 24 V
Output brake +
Output brake M 24 V
motor temperature sensor +
motor temperature sensor -

Size 3 and 4:
Power connection on top
Motor connection on bottom

frontside

Size 4:
fan power supply external,
230V AC
backside

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b maXX 4400, Connections, b maxx 445x and b maxx 446x


+ 24 V
Output brake +
Output brake M 24 V
motor temperature sensor +
motor temperature sensor -

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Size 5 and 6:
Power connection and

frontside

Motor connection on bottom

Fan power supply:


external, 230V AC

net

net

net
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b maXX 4400, Connections, b maxx 447x

Ba-

1C1 1D1 1U1 1V1 1W1

Size 7:
Power connection and
Motor connection in the front

Fan power supply:


external, 230V AC
1W2
1V2
1U2

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b maXX 4400, Monitoring

Power supply monitoring


split in three groups:

Voltage monitoring
Current monitoring
Temperature monitoring

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b maXX 4400, Monitoring

Voltage monitoring:
Mains voltage:
- Net fail

Warning to controller

BBLT enable

- Voltage range

Warning to controller

BBLT enable

Error to controller

BBLT

disable
Warning to controller

BBLT enable

- Undervoltage threshold Warning to controller

BBLT enable

- Phase fail
DC link voltage:

- Overvoltage threshold Error to controller

BBLT

disable
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b maXX 4400, Monitoring

Current monitoring:
Overcurrent (Motor):

Error to controller

Threshold = 1,3 * IMax


IMax = Overload factor * Inom

BBLT disable
Power section switch off

Earth current (Motor):


- BM 441x, BM 442x

no earth current monitoring


Error to controller

- BM 443x to BM 447x
disable

BBLT

Power section
switch off
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b maXX 4400, Monitoring

Temperature monitoring:

Transistor heat sink temperature:


Warning threshold:

parameterizable

Error threshold:

depending on size
e.g. size 3: 85 C

Inside temperature:
Warning threshold:

parameterizable

Error threshold:

depending on size
e.g. Size 1: 79C

Motor temperature:
Warning threshold:

parameterizable

Error threshold:

parameterizable
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Warning threshold
exceeded
Warning
to controller
BBLT enable
Error threshold
exceeded
Error
to controller
BBLT disable
Power section
switch off
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b maXX 4400, Ready-for-use

Ready-for-use (BB)

Calculation
BBController

Output

BBLT

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BB

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Switching Cabinet
external
internal

b maXX 4400, Cooling variants

Air internal

Water internal

Air external

Cold Plate

Water external

BM4XXX - XXX - XXXX - XX


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Bmaxx 44xx Controller

bmaXX 44xx
ControlleR

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b maXX 4400, Controller cassette

2 variants

2-row: Size 1

3-row: size 1-7

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b maXX 4400, Module slot

Designation:

X3-4
Pin designation
Interface number
Interface designation

Module slot

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b maXX 4400, Electronic supply

X100:

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X100-1:

+24V

X100-2:

+24V

X100-3:

Mains Bus

X100-4:

Ballast Bus

X100-5:

M24V

X100-6:

M24V

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b maXX 4400, Controller PCB

H1:

green:
yellow:
green:
yellow:

torque direction 1
torque direction 2
Release
Power on

H3:

red:

Current limit

H4:

red:

Error/Warning

H2:

X1:
RS232

X4:
7 segment display

X2:
Memory module
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b maXX 4400, Controller PCB

X3:
X3-1:

BB-NO

X3-2:

BB-Voltage supply
(24V, IMax=400mA)

X3-3:

Ground for
X3-4 and X3-5

X3-4:

Quick stop

(24V, IEIN=2mA
L: 0 5V; H: 12 30V)

X3-5:

Impulse release
(see quick stop)

X3-6:

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BB-NC

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b maXX 4400, Controller PCB

Controlling variants:
Speed control (cycle time 125 s)
Current control (cycle time 125 s)
Position control (cycle time 125 s)
Open Loop control (cycle time 125 s)

Operation:
ProDrive

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b maXX 4400, Modules

Difference
Function module

Option module

no Bus
A- E

BACI
slots

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G-M

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Function
Modules

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b maXX 4400, Encoder module

Encoder module
Types:

SINCOS encoder
Sinus Incremental encoder
Square wave Inc. encoder
Resolver

Slots:

A-B
Preferred slot for motor control: A

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b maXX 4400, Incremental encoder emulation

IEE-01
Only:
LC 01/02/03
Signals: RS422
Signal sources :
encoder 1
encoder 2
position set value
Output: increments
1 262143
A, B, Zero track
and inversion
calculation time approx.:
125s
Slot only C
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LC 02/03
SSI
encoder 1
position set value
code
binary or Gray

125s
Slot only B

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b maXX 4400, Digital I/O

Digital I/O
IN 1
IN 2
IN 3
IN 4
OUT 1
OUT 2
OUT 3
OUT 4
24 V
M24 V

Variants:
4 IN / 4 OUT (DIO 01 & FIO 01)

Slots:
A-E
Preferred slot: D

Inputs:
24V, L: 0 to 5V, H: 12 to 30V
DIO-01: IIN=2mA, sample rate 1ms
FIO-01 : IIN=5mA, sample rate 1ms

Outputs:
24V, L: 0 to 5V, H: 12 to 30V
DIO 01/ FIO 01 :
Iout=0,5A, refresh rate 1ms
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b maXX 4400, Analog I/O


Analog I/O
Variants:
2 IN / 2 OUT

Inputs:
10V, Differential
amplifier input
RIN=50k, IIN=0,2mA
Sample rate: 125s
resolution: 12/16/12 Bit

BSA
IN 2 IN 1 www.baumuller.com

slots:
preferred slot: E

Outputs:
10V, short curcuit proof
Refresh rate: 125s
resolution: 11/16/12 Bit

OUT 2 +
OUT 1 +
IN 2 +
IN 1 +
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OPTION
Modules

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b maXX 4400, PLC

PLC:
IEC 61131
programmable by controller interface
32 Bit RISC CPU
2 options:

with remanent marker


without remanent marker

slot momentarily G, H
(in future G to M)

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b maXX 4400, Fieldbus

Option module
characteristics:

- 4 PDOs, 1 SDO, controlword, statusword


- all homing methods
- all objekts supported by b maXX
- Baudrates:
20kBd, 125kBd, 250kBd, 500kBd, 1MBd

Commissioning:

- adjust baudrate on module


- adjust address on module
- plug in module into controller
- adjust communication source (P1001) at
controller
- Mapping from master (see manual)

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b maXX 4400, Fieldbus

CANsync
Option module
Master Option module:

- refer to Drive Line II


- 2 WRC, 2 RDC, 1 CC
- Baudrates:
125kBd, 250kBd, 500kBd, 1MBd

Slave Option module:

- refer to Drive Line II


- 2 WRC, 2 RDC, 1 CC
- Baudrates:
125kBd, 250kBd, 500kBd, 1MBd

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b maXX 4400, Fieldbus

Option module (slave):


connected only to controller
protocol:

SERCOS 2, IEC 61491

process data communication:

telegram 3 (speed control), telegram 4 (position control),


telegram 7 (free configurable)

service data communication:

via cyclic data channel

status indication:
adress adjustment:

7 segment display, 2 LEDs


1 rotary switches (hexadecimal) and parameter

baudrate adjustment

automatic detection

number of Slaves:
line length:
baudrate:
connection techn. a. medium:

max. 255 slaves


0 400m (depending on the transmitter power)
2 MBit/s to 16 MBit/s (depending on the line length)
IEC 61491, fibre optic cable

cycle time:

1ms or more

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b maXX 4400, Fieldbus

Option module (slave):


Fastest Fieldbus amoung all
Data Transfer Rate : 100 Mbps
Connected Max upto 255 Slaves
Standard IP setting for communication
EtherCAT master as well as
Slave available in Bmaxx 4400 &
in Controller PLC

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b maXX 4400, Fieldbus

Option module (slave):


connected to controller

PROFIBUS DPV0

protocol:
process data communication:

connected to PLC

8 setpoint and 8 actual values

je 244 Byte Soll- und Istwerte

(opt. status- u. controlword)


service data communication:
configuration tool:

via PKW mechanism


GSD file

4 LEDs

status indication:
adress adjustment:

2 rotary switches (hexadecimal)


automatic detection

baudrate adjustment
number of Slaves:
line length:
baudrate:

via cyclic
data Datenkanal
ber
zyklischen
channel
Feldbuskonfigurator,
fieldbus configurator,GSD-Datei
GSD file

32 per segment (max. 126 slaves)


1200m 100m (depending on the baudrate)
9,6 kBit/s to 12 MBit/s (depending on the line length)
SUB-D-Stecker, 9-pin

connection technology:

2 wire technology

communication medium:
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b maXX 4400

b maXX
44xx

TROUBLESHOOTIN
G

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b maXX 4400, Errors, Troubleshooting

Error, Troubleshooting:
2 Error variants
Error with parameterizable
reaction

Error with immediate


impulse inhibit

Drive inhibited
immediately

possible reactions:
Impulse inhibit
run down with RFG ramp
run down with quick stop ramp
run down with current limit
no reaction

Attention!
No braking is possible

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b maXX 4400, Errors, Troubleshooting

Error Acknowledgement:
5 Variants:
Error Acknowledgement by ProDrive
in Controlword BM_w_Controlword insert 128dez (or 80hex)
by switching the impulse release
by switching a digital input
switching appliance off and on

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Error detection and troubleshooting


b) What to do if there is an error?

Error!

read out the


error number!
(see following
pages)

Remove the cover!

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Error detection and troubleshooting


c) How to read out the error number
In the status error the error numbers are shown in the display.
Only the errors are shown, which enable an error reaction in
the drive or have enabled one. Errors without reaction and also
warnings are not displayed.
The display of error No. starts therewith, that F is shown for
1.5 s. Then the three error code positions are displayed. The
separate figures are displayed for about 0.8 s, interrupted by a
short pause. If there are other errors, these are displayed in the
same manner. The procedure is repeated as soon as all errors
were displayed.
Example: Error 125 and 91 are existing:

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Error detection and troubleshooting


d) Error meaning and troubleshooting

b maXX 4400

e) Error meaning and troubleshooting

b maXX 4100

Power off and on 24V supply

General:

Now the b maXX was reseted!

No

Error was
fixed!

Error appears
again?

Yes

See list of
errors!
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Display

Status

Meaning

Inhibit Start

Initialization completed Error


Free

Ready to Start

Pulse Inhibited

Switched On

No Torque generation yet

Operation Enabled

Pulse Enabled, Motor On

Error

Display will show error


message

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Error Code

Error Power
Supply
:
Meaning

Remedy

64

Mains Failure

Check incoming mains supply

65

Phase Failure

Check all the Phases

66

Mains Undervoltage

Check incoming mains supply

67

Mains Overvoltage

Check incoming mains supply

81

Heat sink Over


Temperature

Let device to cool down

82

DC Link Over voltage

Reduce DC link display

83

Over Current

Reduce the load; call to


Baumuller

84

Ground Current

Check Earthing & 24M


connections

89

Power Unit not Ready


for Operation

Complete the readiness to start


the drive

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Error Motor
:
Error Code

Meaning

Remedy

96

Short Circuit
Temperature Sensor

Check the Connection at X101


connector.

97

Temperature Sensor
not connected

Make connection from X101 to


Motor K+ & K-

98

Motor Over
Temperature

Allow the Motor to cool down

99

I^2t Limit Exceeded

Keep drive ideal for 15 min.

208

Drive Blocking

Check the U V W output


sequence to the Motor.

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Error
Encoder:
Error Code

Meaning

Remedy

112

Encoder Communication
Error

Contact Baumuller

115

Cable Break Encoder 1

Remove the breakage of the


Cable

116

Over speed of Encoder 1

Check the allowable rotational


speed for Encoder.

118

Encoder type Unknown

Check whether card is correct.

146

Encoder Module Missing

Remove Reinsert ENC 02


Card.

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Error Messages

K. Wirsching

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K. Wirsching

9. Service & Support in case of an error

Support - Categories

L1 = Level 1

L2 = Level 2

L3 = Level 3

on-site first level support, own activity and knowledge to rectify


upcoming issues directly through personal of the machine user

Case of unresolved issues, machine user contacts machine builder


company HERKULES

user and/or machine builder contacts company BAUMLLER local


subsidiary or head-quarter in Nuremberg for further support

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Program Upload and


Download using ProDrive Software

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Communication of Unit with PC

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(1) Communication is possible either on RS 232 ( Serial ) or Ethernet Interface.


(2) For RS 232 communication purpose you will need Straight Cable ( pin 1-9)
with 9-pin Male connector on Drive side & 9-pin Female connector on PC side.
(3) For Ethernet communication also it is necessary to have straight cable with
RJ-45 connector.
(4) Now connect cable ( Either Ethernet Or RS 232 serial) to X1 connector on
drive side & other end to your PC.

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Set communication parameters

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(5) Open the ProDrive_ver_1.13 software then you will see the new window on
screen as shown below.

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Check communication

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(6) Once you click on Start Prodrive wait for some time & you will see the
below window.

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Start ProDrive

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(7) Further click on Connect then new window will open as shown below &
select Only establish online connection & click on OK.

(8) Then at the bottom side you can see the online status with Green Colour.

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Program Upload

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(9) Program Uploading :

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Program Download

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(10) Program Download :

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Program Saving

K. Wirsching

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Program Download

K. Wirsching

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Servo Modes of
Operation

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Servo Modes of Operation :

K. Wirsching

Auto-Tuning Mode
Synchronous Operation Mode
Speed Control Mode
Position Control Mode
Positioning
Jog Operation Mode
Homing Mode
Velocity Mode
Find Notch Position

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Servo Modes of Operation :

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Auto-Tuning Mode

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Servo Modes of Operation :

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Synchronous Operation Mode

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Servo Modes of Operation :

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Speed Control Mode

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Servo Modes of Operation :

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Positioning Mode

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Servo Modes of Operation :

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Jog Operation Mode

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Servo Modes of Operation :

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Homing Mode

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Servo Modes of Operation :

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Find Notch Position Mode

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Control-Word
&
Status-Word

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K. Wirsching

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