b maXX 4000

Modular servo drive

b maXX has up to eleven inserts for plug-in modules and can therefore be individually adapted for
special automation tasks. Special plug-in modules interface b maXX, including interface adaptors for
most standard bus systems. The plug-in b maXX-drivePLC module provides integrated intelligent control.

24
Function and option modules for b maXX 4400

With more than 30 different function and option can secure a wide variety of functions and configure
modules b maXX can easily be adapted in line with the appropriate combinations on their own. In this
the individual tasks of the automation and drive way, he can react quickly and flexibly to new
solution. requirements.

The individual modules are designed as plug-in This system also ensures that the drive can be
boards and therefore the drive controller no longer quickly expanded at the user‘s facility. Production
has to be ordered as a preassembled unit. By using adjustments can be implemented within a short
various plug-in boards, the machine manufacturer space of time and with minimal effort.

1–2 encoders

encoder b maXX-
emulation drivePLC

digital I/Os field bus

analogue I/Os IEI card

storage module

www.baumueller.com 25
 Digital I/Os Analog I/Os
• 4 inputs, 24 V industrial logic, • 2 inputs ± 10 V 12 Bit and
isolated 2 outputs ± 10 V 8 Bit
• 4 outputs, 24 V industrial logic, • 2 inputs ± 10 V 16 Bit and
isolated, 0.5 A 2 outputs ± 10 V 16 Bit
• 2 inputs ± 10 V 12 Bit and
2 outputs ± 10 V 12 Bit
• 2 inputs 4–20 mA, 16 Bit,
Encoder Interfaces
2 outputs ± 10 V 16 Bit
• SinCos encoder
With hiperface interface and
electronic rating plate. Resolution: Field bus modules for b maXX 4400
up to several million incr./rev.
• Resolver, resolution: 1024 incr./rev. b maXX 4400 supports all
• 5 V-square-wave incremental en- conventional field bus
coder, res.: (stroke no. x 4) incr./rev. systems. b maXX can be
• SinCos encoder with EnDat® interface optimally integrated into all
Sine/cosine encoder with EnDat 2.1 and 2.2 inter- systems by simply replacing
face for single and multiturns, length measure- the corresponding option
ment systems and absolute position recognition. module. EtherCAT is the
• SinCos encoder with SSI interface standard field bus.
Sine/cosine encoder with SSI standard interface,
with internal and external encoder power
supply. Field bus interfaces
• Incremental encoder emulation
5 V-square-wave/differential signal, Field bus b maXX 4400 b maXX-drivePLC
90° phase shift EtherCAT Slave Slave, Master, Cluster
EtherNet/IP Slave -
CANopen Slave Slave, Master
CANsync Slave Slave, Master
Storage module
Profibus Slave Slave
The parameter storage module contains Sercos Slave -
all the parameters that are set on the Varan Slave -

drive controller of the b maXX for all 8 POWERLINK Slave Slave

Ethernet TCP/IP TCP/IP
parameter data records and all 16
positioning profiles. New parameters
can be loaded to the drive controller
simply by plugging in the module.
Given that the parameter module is pluggable, a
drive can be replaced during servicing without the
need for any knowledge of the operating software.
Servicing could not be easier.

26
 b maXX-drivePLC

Clever. Fast. Effective.

The b maXX-drivePLC module makes the drive in- Speed up your applications
telligent. This in-drive control intelligence allows • Makes drives user-programmable
very fast access to the setpoints and actual values
• Delivers excellent real-time performance
of the drive controller. Therefore, the functionality
• Increases availability
of the drive can be enhanced with complex mo-
tion, control and technology functions. This en- • Reduces control cabinet size
sures that the application can be created quickly • Ensures a consistently stable system
and economically.

www.baumueller.com 27
 In-drive PLC

With a cycle time of 100 μs for 1,000 lines of STL, existing EtherCAT master challenging and highly
the b maXX-drivePLC is suitable for both compre- synchronized movement processes are controlled
hensive control and demanding motion control directly on the b maXX-drivePLC. The extensive
tasks. Through the use of our drivePLC, the PLC product range includes decentralized analog and
can be assisted, down-sized or even completely digital I/O modules.
replaced. A new transparency and clarity is also
created in the application via the clean decoupling The program memory of the b maXX-drivePLC is
of motion control applications from the machine sufficient for typical 120,000 lines of IL. 2 MB of RAM
program. The drivePLC can be integrated into the are available for variables. The optional residual
b maXX 4400 servo controller series and enables data memory of 100 KB is buffered battery-free
the uncomplicated creation of control technology with a NVRAM. This means there is enough memory
programs with ProMaster or PROPROG. available for sufficient code. Costly memory ex-
pansions can be dispensed with. The battery-free
A CANopen master is included with the CAN option NVRAM means that data is available maintenance-
module for b maXX-drivePLC. This enables up to free and after every time the system is switched
65,536 digital I/O points to be switched. With the off and on without any data loss.

b maXX HMI
• 32-bit Risc CPU 120 MHz
• 16 MB flash memory, of which
2 MB is reserved for the
IEC program and 4 MB for cams
• 100 KB non-volatile RAM

IEC 61131-3 Axis Multi Axis Advanced library Machine module

28
 PLC and drive are synchronous

The in-drive PLC can have synchronized access to all setpoints and
actual values of the drive controller via the internal parallel bus.
Therefore, time-consuming communications programs do not
have to be created. The signal transit times are reduced to a mini-
mum. This greatly enhances process security and also increases
the availability of the system.

Further details on how b maXX

4400 can be extended into a
complete automation system can
be found in the brochure with the
title “Automation”.

All the advantages at a glance

• Fast, synchronous PLC access to the drive controller:

Sophisticated communications programs are no longer required — the burden
on the system is relieved
• No wiring between the PLC and the drive:
Fault-prone cable connections can be reduced — availability is increased
• Compact design saves control cabinet space:
The volume of the control cabinet can be reduced
• Maximum PLC and servo controller performance due to independent processors:
No limitations due to overlapping processes — the system remains stable and reliable
• Baumüller is the contact partner for the PLC and drive system, and therefore the
automation system as a whole: Experience and competence for the entire automation
system — direct communication with one reliable partner reduces the amount of
engineering that is required

www.baumueller.com 29
 b maXX 4400 – The modular servo drive

Braking energy Types of cooling

Brake resistor activation is integrated in the form of a

brake chopper. A regenerative resistor is connected exter-
nally. This paves the way for optimal dimensioning and
also reduces the volume of the control cabinet.
Standard
cooling air
Line filter

To optimize configuration from a cost perspective, line

filters are always connected in series outside the device.
Several power modules can thus be grouped for each line
filter resulting in reduced costs for the system as a whole.

Temperature-dependent fan control

Cold plate
The fan is controlled relative to the temperature inside
the device. This leads to a reduction in energy consump-
tion and therefore lowers the overall costs of a system.

DC link coupling

DC link coupling can be achieved for a number of power

modules for the purpose of energy compensation. Surplus
energy is not “burned”. It is made available to other drive Push-through
units without taking additional energy from the supply cooling air
network.

Safety module

With the optional safety module, the option “safety stop”

in accordance with EN ISO 13849 safety category 4 can
easily be realized without the integration of additional
Push-through
contactors in the motor line. This ensures that the struc-
cooling water
ture of the safety circuit remains simple and transparent.
The danger potential of the machine is reduced — the
machine works reliably.

30
b maXX 4400 servo drive family

b maXX 4400 offers a performance range from

1.1 kW to 315 kW. All devices have integrated Safety functions acc.
rectifiers, DC link capacitors and inverters. to IEC 61800-5-2

Technical data
b maXX 4400
Frame size 1S 1B 2 3 4 5 6 7

IN IMAX typ. motor rating Overload Dimensions

Type Frame size [A] [A] [kW] [hp] factor W x H x D 1) [mm]
4412 1S 2.5 5 1.1 1.5 2 80 x 310 x 263 4)
4413 1S 4.5 9 2 2.7 2 80 x 310 x 263 4)
4412 1B 2.5 5 1.1 1.5 2 106 x 310 x 263 4)
4413 1B 4.5 9 2 2.7 2 106 x 310 x 263 4)
4422 2 7.5 15 3.4 4.6 2 106 x 428 x 340 / 320
4423 2 11 22 5 6.7 2 106 x 428 x 340 / 320
4424 2 15 30 6.8 9.1 2 106 x 428 x 340 / 320
4425 2 15 40 2) 6.8 9.1 2.6 106 x 428 x 340 / 320
4426 3) 2 22.5 45 2) 6 8.0 2 106 x 428 x 340 / 320
4426 2 22.5 45 2) 10 13.4 2 106 x 428 x 340 / 320
4432 3 22.5 45 10 13.4 2 155 x 510 x 340 / 325
4433 3 30 60 13 17.4 2 155 x 510 x 340 / 325
4434 3 45 90 20 26.8 2 155 x 510 x 340 / 325
4435 3 60 90 28 37.5 1.5 155 x 510 x 340 / 325
4443 4 80 120 36 48 1.5 190 x 624 x 374 / 327
4444 4 100 130 45 60 1.3 190 x 624 x 374 / 327
4445 4 130 170 58 78 1.3 190 x 624 x 374 / 327
4446 4 150 200 75 100 1.3 190 x 624 x 374 / 327
4453 5 150 195 75 100 1.3 307 x 656 x 374 / 321
4454 5 210 260 110 147 1.3 307 x 656 x 374 / 321
4462 6 250 325 132 177 1.3 437 x 815 x 378 / 316
4463 6 300 390 160 215 1.3 437 x 815 x 378 / 316
4466 6 350 450 175 234 1.3 437 x 815 x 378 / 316
4472 7 450 585 225 302 1.3 520 x 600 x 340 5)
4473 7 615 780 315 422 1.3 520 x 600 x 340 5)

Supply voltage: 207–528 V ± 0% AC Electronics supply: external 24 V DC (diagnostic capability) 1) Depth air cooling / depth water cooling
Supply frequency: 50/60 Hz Fan connection: frame size 1–3: 24 V DC electronics supply 2) for 1 second
Supply rated voltage: 400 V frame size 4–7: 230 V AC ± 10% 3) single phase
DC link voltage: 540 V rated voltage Certification: CE, CSA, UL 4) air cooling only
Chopping frequency: 2/4/8 kHz 5) water cooling only
Output voltage: 0–95% of supply voltage Subject to alteration Height and depth w/o mounting brackets; depth
incl. required bending radius of connecting cables

www.baumueller.com 31
 b maXX 4100
Regenerative power supply unit

It is often the case with electrical drives that energy costs

make up almost 90% of the overall life-cycle costs. With
this in mind, regenerative systems help to reduce the total
cost of ownership.

Baumüller’s tried-and-tested b maXX automation mains supply rather than wastefully dissipating
and drive solution is being expanded with the this energy as heat.
addition of the new b maXX 4100 series regenerative From the standpoint of energy costs, this offers the
power supplies. These units work in conjunction user considerable savings over the machine’s service
with b maXX 4400 series units, and can supply the life. Regenerative systems help to lower energy con-
DC link voltage to one or more drives. By using a b sumption (and do their bit for the environment) by
maXX 4100, all excess regenerative brake energy feeding the available brake energy back to the power
generated by the system is returned to the AC grid rather than wasting it via a regenerative resistor.

32
The b maXX 4100 units are fully integrated into
Baumüller’s b maXX automation and drive solution
family of products. The benefits which the b maXX Mains Voltage Mains filter
limitation
series offers to its users such as modularity and contactor

flexibility, are also provided by the b maXX 4100. Mains chok

e

Four different frame sizes cover a DC link power

range of 35 kW to 150 kW with the option of air
or water cooling. The b maXX 4100 can also be
integrated in the Baumüller automation environ-
ment by means of various optional fieldbusses.
System consistency is achieved by adopting the
same housing technology and connection arrange-
ments as well as integrating the parameters of the detect
ion
System
b maXX 4400 into the existing b maXX ProDrive s con
tacto
r
Main dback
fee
operating software. s con
tacto
r
Main ntrol
co

• Regenerative brake energy is returned as a

e
harg
sine wave Prec ry
it
circu

• 3 frame sizes with 35 kW to 150 kW ging

Char tor
ta c
• 60 second overload capability con

• Current-controlled charging circuit

• Integrated control of charging and mains
contactors
• Integral regenerative switching transistor
• Monitoring of mains, charging connection, mains
contactor, DC link voltage, and heat sink tem-
perature
• Optional fieldbus modules

Technical data b maXX 4100

Frame size 3 4 6

DC link power 1) DC link peak power Overload Dimensions

Type Frame size [kW] [hp] [kW] [hp] factor 2) W x H x D 3) [mm]
4135 3 35 47 52 70 1.5 155 x 510 x 340
4145 4 80 107 104 139 1.3 190 x 624 x 374
4163 6 150 201 190 255 1.3 437 x 815 x 378

Supply voltage: 360–528 V ± 0% AC Electronics supply: external, 19.3–30 V DC (diagnostic capability) 1) For 640 V DC DC link rated voltage
Supply frequency: 45–65 Hz Fan connection: frame size 3: 24 V DC electronics supply 2) For 60 seconds
Supply rated voltage: 400 V AC frame sizes 4–6: 230 V AC ± 10% 3) Height and depth without mounting
DC link rated voltage: 640 V DC Certification: CE, CSA, UL brackets; depth including required bending
Switching frequency: 8 kHz radius of connecting cables
Regenerative switching transistor: Integrated Subject to alteration

www.baumueller.com 33
 b maXX 4600/4700
Peak and nominal load devices

Peak and nominal load devices available in five sizes supplement the proven b maXX series. Regardless of whether you require maximum
performance on a continuous or temporary basis — the b maXX series offers customised drive solutions for every application.

The tried-and-tested b maXX automation and high performance is required. As a result, the drive
drive solution is being expanded to include new can be adapted perfectly to the power requirements
peak and nominal load devices from the 4600 and of the relevant application.
4700 series. Baumüller is now able to meet the Although the devices in the series are more power-
specific require-ments of applications in the injec- ful, they have a compact design and take up much
tion moulding or extrusion sector, for example, less space in the control cabinet — double benefits
where either short-term peak output or permanent for the user.

34
b maXX 4600/4700 — Your benefits at a glance

• Optimized drive solution for specific industry requirements

• Different sizes available for compatible drive dimensions Safety functions acc.
to IEC 61800-5-2
• Less space required in the control cabinet due to smaller devices and the use
of water cooling, control cabinet therefore less expensive to manufacture
• Water cooling in the control cabinet provides a cost-effective solution
• Compatible with other devices in the b maXX series

Technical data b maXX 4600/4700

b maXX 4600 IN IMAX Overload Dimensions

Type Frame size [A] [A] factor 1) W x H x D [mm]
4632-F 3 60 120 2 208 x 556.5 x 325
4641-F 4 85 170 2 242 x 681 x 327
4642-F 4 100 200 2 242 x 681 x 327
4650-F 2) 5 130 260 2 360 x 550 x 285
4651-F 2) 5 165 330 2 360 x 550 x 285
4652-F 2)
5 200 400 2 360 x 550 x 285
4661-F 2) 6 250 500 2 490 x 710 x 285
4662-F 2)
6 300 600 2 490 x 710 x 285

b maXX 4700 IN IMAX Overload Dimensions

Type Frame size [A] [A] factor 1) W x H x D [mm]
4755-F 2) 5 260 260 1 360 x 550 x 285
4766-F 2)
6 450 450 1 490 x 710 x 285
4773-F 7 720 800 1.1 580 x 660 x 340

1) for 1 second with a cycle of 5 seconds Subject to alteration

2) compact design, water-cooled

www.baumueller.com 35
 Motors

DSD2 — Dynamic servo motors DSC1 — Compact servo motors

The servo motors for highly The DSC 45-100 is a series of
dynamic applications with high-torque servo motors
the highest requirements of that are up to 30% more
acceleration capacity and the compact than conventional
best start-stop qualities. servo designs.
Sizes 28, 36, 45, 56, 71, 100, Sizes 45, 56, 71, 100, power
132, power range 0.3–150 kW (0.4–200 hp), speeds range 0.5-18 kW (0.67-24 hp), speeds up to
up to 6000 min-1, up to IP65 type of protection 6000 min-1, up to IP65 type of protection

DSP1 — For high speed performance DSH1 — High precision motors

For applications requiring The DSH1 high-precision servo
high rotary speeds, the DSP motors were developed spe-
motors complete the existing cifically for applications with
DSD range. the highest standards for
Sizes 45, 56, 71, 100, quality and smooth operation.
power range 1.2–32 kW Sizes 45, 56, 71, 100, power
(1.6–43 hp), speeds up to 6000 min-1, up to IP65 range 0.5-8 kW (0.68-11 hp), speeds up to
type of protection 6000 min-1, up to IP65 type of protection

46
DS/DS2/DA1 — General purpose servo motors
The servo motor for all applications with strict energy efficiency requirements.
Type DS/DS2: Sizes 45, 56, 71, 100, 132, 160, 200, power range 0.25–295 kW (0.33–396 hp),
speeds up to 6000 min-1, type of protection: unventilated IP54,
ventilated IP23/IP54, water-cooled IP54.
Type DA1: Sizes 100, 132, 160, 180, 225, 280, power range 3.5–400 kW (4.7–536 hp),
speeds up to 8000 min-1, type of protection: ventilated IP23/IP54, water-cooled IP54

DST2 — Powerful high-torque motors

The high-torque motor DST2 for application with maximum torque requirements.
Sizes 135, 200, 260, 315, 400, 560*,
power range 2.7–1150 kW (3.6–1542 hp), speeds up to 1500 min-1,
torque up to 80,000 Nm, IP54 type of protection, water-cooled *) on request

GDM & DSM — Disc motors

Baumüller offers a wide range of disc rotors for use in a large number of different
applications where installation space is at a premium.
GDM DC disc motors: Power range 16–3000 W (0.02–4 hp)
DSM brushless disc motors: Power range 180–6300 W (0.24–8.4 hp)

DSE - Embedded three-phase current synchronous motors

The DSE synchronous motors are available either as a housing version or as a built-
in motor. The motor covering a rotational speed range of up to 9000 min-1 features
buried magnets and therefore impresses with a particularly high power density.

BPx — Planetary gear series

The BPx planetary gear series in combination with our servo motors are ideally
suited for applications with high demands on torque and dynamic.

LSC - Coreless linear motors

The coreless LSC linear motors from Baumüller achieve maximum current and power
rise rates. They are therefore ideal for highly dynamic applications with maximum
resilience against disruptive forces.

DSDI/DSMI — Motors with integrated control/power electronics

The DSDI and DSMI servo motors with integrated control and power electronics meet
the requirements of modern, decentralized drive architectures. The DSDI is a highly
dynamic motor and the DSMI is a high torque servo drive. Power range 170–385 W
(0.23–0.52 hp), speeds up to 6000 min-1, type of protection up to IP65

www.baumueller.com 47
 Baumüller Nürnberg GmbH, Ostendstraße 80–90, 90482 Nürnberg, Phone: +49 (0) 911 5432 - 0, Fax: +49 (0) 911 5432 - 130
Baumüller Anlagen-Systemtechnik GmbH & Co. KG, Ostendstr. 84, 90482 Nürnberg, Phone: +49 (0)  911 54408 - 0, Fax: +49 (0) 911 54408 - 769
Baumüller Reparaturwerk GmbH & Co. KG, Andernacher Straße 19, 90411 Nürnberg, Phone: +49 (0) 911 9552 - 0, Fax: +49 (0) 911 9552 - 999
Baumüller DirectMotion GmbH, Flugplatzweg 2, 37581 Bad Gandersheim, Phone: +49 (0) 5382 9805- 0, Fax: +49 (0) 5382 9805 - 55

All data/information and particulars given in this brochure is non-binding customer information, subject to constant further development and continuously updated by our
permanent alteration service. Please note that all particulars/figures/information is current data at the date of printing. These particulars are not legally binding for the purpose
of measurement, calculation or cost accounting. Prior to using any of the information contained in this brochure as a basis for your own calculations and/or applications, please
inform yourself about whether the information you have at your disposal is up to date. Therefore, no liability is assumed for the correctness of the information.

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