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Application handbook English Language Original Document No. 5.17002.02 Part No. 466346 Status 3-May-2018 b maXX 5000 Servo pump function Firmware-Version V1 Read the Instruction handbook before starting any work! 5.17002.02...
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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....
ENERAL NFORMATION 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.
Explanation of symbols 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.
General Information 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: m Non-compliance with the Instruction handbook m Non-intended use m Use of untrained personnel...
Information concerning the responsible contact person can be obtained at any time by telephone, fax, e-mail or over the internet. Other applicable documents Instruction handbook Doc.-No. Part No. Part No. German English Instruction handbook b maXX 5000 5.09021 439682 439683 Instruction handbook b maXX 5500 5.13008 446683 446684 Parameter manual Doc.-No.
ONTROL TRUCTURES This chapter describes the structure of the servo pump function in the b maXX controller. The control model is described by using graphics. Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 of 76...
Overview of operating pages Overview of operating pages Servo pump functionalities can be set in ProDrive: Figure 1: Servo pump V1: General Figure 2: Servo pump V1: Adaption Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH of 76...
Signal processing of set values Signal processing of set values 2.2.1 Volume set values and pressure set values via field bus Interface overlaid control P 177.042 in ml/min P177.35 Scaling Field bus P177.042 P177.042 Volume set Qset Qset Qset filtered value ml/min ml/min...
Control Structures Signal processing of actual values 2.3.1 Interface pressure actual values if add-on module SVP is available Interface 0-10 V pressure sensor Add-on module SVP analog input 3 IF P177.3 0/4-20 P177.175 Bit 7 = P176.67 P176.66 P176.68 Pressure actual TRUE P_actual Sca-...
Scaling and ramps of volume set values 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–...
Control Structures Adaptation of the pressure controller parameters (kp, Tn) Depending on control differences the pressure controller parameters can be dynamically changed during the operating time. Adaptation P177.195 P177.122 P177.196 Pressure Controller P177.197 Proportional amplification P177.198 P177.199 P177.62 P177.200 P177.201 Integral P177.202 action time...
Speed stop at minimum pressure values 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.
Control Structures 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.
2.10 Switching pressure sensors 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).
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. 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.
Reading in of pressure and volume set/actual values 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 Add-on module SVP as analog interface (see Zpage 20–)
Installation Pin assignment Figure 17: Pin assignment SVP-001-00X as analog interface Depending on the used add-on module SVP the following signal forms are required: m Volume set value interface (Analog input 1 of add-on module SVP): SVP-001-001/2 Voltage input (0 - 10 V) Volume set value from 0 - 10 V is required.
Reading in of pressure and volume set/actual values 3.2.2 Field bus combined with add-on module SVP In the case the pressure and volume set value are set via field bus parameters: m Volume set value interface: ZP177.42– Q Set value field bus DINT Scaling: ml/min m Pressure set value interface:...
Installation Pin assignment Figure 19: Pin assignment field bus combined with SVP-001-00X Depending on the used add-on module SVP the following signal forms are required: m Pressure actual value interface (analog input 3 or 4 of add-on module SVP): ...
Reading in of pressure and volume set/actual values 3.2.3 Field bus combined with standard analog IO X6 In this case the pressure and volume set value is set via field bus parameter: m Volume set value interface: ZP177.42– Q Set value field bus DINT Scaling: ml/min Pressure set value interface :...
Installation Pin assignment Pin No. Assignment Actual pressure value sensor 1 + Actual pressure value sensor 2 + OUT 1 - , OUT 2 - OUT 1 + OUT 2 + Actual pressure value sensor 1 - Actual pressure value sensor 2 - OUT 1 - , OUT 2 - OUT 1 - , OUT 2 - D-sub connector 9-pin...
Add-on module SVP Add-on module SVP The add-on module SVP provides an I/O-extension. The add-on module SVP has to be mounted in production, it’s not pluggable or can be retrofitted. Up to now there are three types of add-on module SVP. Module with additional analog/digital inputs/outputs, BM53XX-XXXX-XX04...
Installation Analog inputs Voltage input Current input Resolution 14 bit Type differential input ca. 100 Input resistance ca. 50 k Input current max. 250 µA min. (0) 4 A, max. 20 mA Input voltage -10 V to +10 V max.
Add-on module SVP All analog IOs must be released via parameter ZP177.2–. In Parameter ZP177.3– oversampling can be set and furthermore the range of current signal (0 - 20 mA or 4 - 20 mA) can be selected. In the following table is defined which add-on module is required regarding set and actual value signal form.
Installation 3.3.2 Connection pressure sensor with voltage interface Connection example for a pressure sensor with voltage output (3-wire version): Supply 24 V Output 0..10 V Pressure sensor Pressure Transmitter Figure 24: Typical connection pressure sensor with voltage interface The 24 V supply of pressure sensor is directly supplied by the add-on module SVP. Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 of 76...
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Add-on module SVP Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH of 76...
OMMISSIONING This chapter describes the guided commissioning function of the servo pump in the b maXX 5000. The guide is described using graphics and a short of explanation. Start h Start the guided commissioning by clicking on „Start guided commissioning“ at the ...
Start h Select the desired add-on to begin the commissioning. Figure 26: Guided commissioning: First window h Click on „Continue“ Device data: The actual drive-type. PWM frequency: Select the desired PWM frequency for running the motor. DC link voltage: Shows you the actual DC link voltage. Figure 27: Guided commissioning: Power unit h Click on „Continue“...
Guided Commissioning h Select the used encoder type by clicking on „Encoder database“. Please ensure you select the right encoder to prevent any damage to the used encoder due to overvoltage. Figure 28: Guided commissioning: Selecting the encoder h Click on „Continue“ h Select a motor either from the „Motor database“...
Start NOTE! It is advised to set the „Speed set value positive limit“ on beginning to zero, to pre- vent any damage on the servo pump. Figure 31: Guided commissioning: Essential parameter settings h Click on „Continue“ h If known, set the load inertia. Set the controller settings to „hard“.
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Guided Commissioning h Click on „Accept operator's control“ and click on „Yes“ on the occurred dialog. Figure 33: Guided commissioning: Operator‘s control h Click on „Continue“ h Click on „Reset errors” if necessary (errors displayed under „Error“). Figure 34: Guided commissioning: Check the releases h Click on „Continue“...
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Start h Click on „Start“ to begin the Self-optimization of the current controller. The stator resistance, inductance Lq and the inductance Ld of the motor is measured. Wait until the measurement is done. Figure 35: Guided commissioning: Self-optimization h Click on „Continue“ Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH...
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Guided Commissioning h Find the notch position if not known. Click on „Start“ and wait until the notch position has been found. Figure 36: Guided commissioning: Finding the notch position h Click on „Continue“ Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 of 76...
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Start h Check now whether the motor is rotating or not. NOTICE! Make sure that the valves are turned in the way that the pump delivers directly into the tank. Otherwise damage may occur. Figure 37: Guided commissioning: Rotating the motor h Click on „Continue“...
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Guided Commissioning h Click on „Activate servo pump“. Check whether the PLC state is running (green) or not. h If there are any error's, please contact the Application-Department of Baumüller. Figure 38: Guided commissioning: Activate the servo pump h Click on „Continue“ h Set the pressure range for the pressure sensor and the flow rate of the pump.
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Start h Set here the „SP Speed set value positive limit“ and the „SP Speed set value neg- ative limit“. Figure 40: Guided commissioning: Speed limits h Click on „Continue“ Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH of 76...
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Guided Commissioning h Select the set value and actual value interface Figure 41: Guided commissioning: Set value and actual value interface h Click on „Continue“ If your choice is „Analog“, continue reading Zpage 45–. Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 of 76...
Commissioning set /actual values via fieldbus Commissioning set /actual values via fieldbus h Select „Synchronizing off or on“ as needed and set the Fieldbus values depending on your application. Figure 42: Guided commissioning: Fieldbus configuration h Click on „Continue“ h Check the fieldbus process data mapping. Figure 43: Guided commissioning: Data mapping h Click on „Continue“...
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Guided Commissioning h Reset the operator's control by clicking on it. Figure 44: Guided commissioning: Operation control h Click on „Continue“ h Set the scaling of the volume set value. Figure 45: Guided commissioning: Scaling volume set value h Click on „Continue“ Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 of 76...
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Commissioning set /actual values via fieldbus h Set the scaling of the pressure set value. Figure 46: Guided commissioning: Scaling pressure set value h Click on „Continue“ If you have set either „Fieldbus with standard module“ or „Fieldbus with add-on mod- ule“, continue reading Zpage 47–.
Guided Commissioning Commissioning set /actual values via analog interface h Set the scaling of the „Volume set value“. Figure 47: Guided commissioning: Scaling pressure set value h Click on „Continue“ Here you can check the previous made scaling settings for the „Volume set value“. Figure 48: Guided commissioning: Check volume set scaling h Click on „Continue“...
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Commissioning set /actual values via analog interface h Set the scaling of the „Pressure set value“. Figure 49: Guided commissioning: Scaling pressure set value h Click on „Continue“ h Here you can check the previous made scaling settings for the „Pressure set value“. Figure 50: Guided commissioning: Check scaling pressure set value h Click on „Continue“...
Guided Commissioning Setting the pressure sensor inputs h Select the input on which the pressure Sensor is connected to. Sensor input 1 with add-on module: SVP, analog input Sensor input 1 without add-on module SVP: Standard-IO X6, analog input Sensor input 2 with add-on module: SVP, analog input Sensor input 2 without add-on module SVP: Standard-IO X6, analog input...
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Setting the pressure sensor inputs h Check the scaling of the „Pressure actual value“. Figure 53: Guided commissioning: Check scaling pressure actual value h Click on „Continue“ h Set the pressure control parameters between soft and hard for the Kp and Tn values. h Download the data to the controller.
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Guided Commissioning h Only if necessary, activate the pump protection and set the pump protection values. If the „N/Q actual value“ is greater than the threshold value AND if the „P actual value“ is smaller than the threshold value, an error will be generated after the set „recognition time“...
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Setting the pressure sensor inputs h By clicking on „Save all“ you can now save your settings in the Flash. h By clicking on „Upload“ you are able to save all your settings on a local computer. Figure 57: Guided commissioning: Save data h Click on „Continue“...
RROR ESSAGES The following table shows all Servo pump related errors with the Code, RC value, reaction and description: Code Reaction Description Firmware and PLC project 1200 RC_INCOMPATUBLE_PLC_PRJ Stopping drive versions does not match. 1201 RC_WIRE_BRAKE Stopping drive Sensor wire brake occurred. 1202 RC_PUMP_PROTECTION Stopping drive...
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Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH of 76...
ARAMETERS In this chapter we describe the parameters which are available, sorted by numbers. WARNING! Danger from modification of the parameter settings! The danger is: mechanical and electrical danger m The change of parameters affects the behavior of the Baumüller-unit and conse- quently the behavior of the construction and its components.
Structure of the parameters Structure of the parameters Every parameter has m a name, m an unique number, m a data type, m and fixed attributes or characteristics. Reserved bits In the description of parameters, especially in mode parameters and status parameters, some bits are identified as reserved.
Parameters Parameter description 176.1 Mode DWORD 0x00000000 to 0xFFFFFFFF Activation of the analog input and output channels: Meaning 1: Switch on channel analog input 1 0: Switch off channel analog input 1 1: Switch on channel analog input 2 0: Switch off channel analog input 2 1: Switch on channel analog input 3 0: Switch off channel analog input 3...
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Parameter description 176.2 Mode analog inputs DWORD 0x00000000 to 0xFFFFFFFF Configuration of the analog inputs Meaning Bit 0 … 23: Oversampling Oversampling factor: 0 … 8 3 … 0 Oversampling factor analog input 1 7 … 4 Oversampling factor analog input 2 11 …...
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Parameters 176.7 Status digital outputs WORD 0x0000 to 0xFFFF Status of the digital outputs Meaning Status digital output 1: 0: disabled 1: active Status digital output 2: 0: disabled 1: active Status digital output 3: 0: disabled 1: active Status digital output 4: 0: disabled 1: active...
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Parameter description 176.10 Value analog input 3 FLOAT -25 to +25 Sensor 1 Pressure actual value from add-on module SVP. Scaling: Voltage input: = 1,0 Current input: 1 mA = 1,0 176.11 Value analog input 4 FLOAT -25 to +25 Sensor 2 Pressure actual value from add-on module SVP.
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Parameters 176.19 Value analog output 4 FLOAT -11 V to +11 V Analog output 4 of add-on module SVP is hard-linked to motor temperature (P128.3). Scaling: 0 V -10 V = 200 °C 176.60 User scaling factor add-on module AI1 FLOAT -1000000000.000 to 1000000000.000 Scaling factor volume set value in case of analog set values.
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Parameter description 176.66 User scaling factor add-on module AI3 FLOAT -1000000000.000 to 1000000000.000 Scaling factor pressure actual value sensor 1 from add-on module SVP. 176.67 User offset add-on module AI3 FLOAT -10 V to +10 V Offset pressure actual value sensor 1 from add-on module SVP. 176.68 User filter add-on module AI3 ...
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Parameters 177.2 Status word DWORD 0x00000000 to 0xFFFFFFFF Status word of servo pump. Meaning 0 … 12 Reserved Pump protection: 0: disabled 1: active 14 … 15 Reserved 177.3 Controlword 1 DS-support WORD 0x0000 to 0xFFFF Control word 1 of servo pump. Meaning Adaption of pressure controller parameter 0: disabled...
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Parameter description 177.4 Controlword 2 DS-support WORD 0x0000 to 0xFFFF Control word 2 of servo pump. Meaning 1 … 3 Reserved Pump protection 0: disabled 1: active 5 … 11 Reserved Negative volume set values 0: prohibited 1: allowed 13 …...
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Parameters 177.34 n/Q set value unfiltered DINT -32768 to 32767 Input value of the volume set value. Display in the ProDrive depending on the settings of page „Servo pump - general“ in rpm or in l/min. Scaling: 32767 Inc = Motor maximum speed * 2 177.35 n/Q set value filtered...
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Parameter description 177.41 n/Q set value scaled DINT -32768 to +32767 Set volume value according to scaling through the scaling divisor parameter ZP177.40– . Display in the ProDrive depending on the settings on page „Servo pump - general“ in rpm or in l/min. Scaling: 32767 Inc = Motor maximum speed * 2 177.42...
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Parameters 177.125 Integral part PI controller DINT -2147483648 to +2147483647 Integral part PI pressure controller Scaling: 1073741824 Inc = Max. drive Speed (P110.13) 177.144 P Set value minimum 0 to 32767 Limit for Pressure set value. If actual Pressure is smaller than „P Act value minimum“ and set pressure is smaller than „P Set value minimum“...
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Parameter description 177.167 Pump protection n/Q recognition threshold DS-support DINT 0 to 2147483647 Speed threshold for pump protection functionality. Scaling: 1073741824 Inc = Max. drive speed (P110.13) 177.168 Pump protection P actual value threshold DS-support DINT -32768 to +32767 Actual pressure threshold for pump protection. Scaling: 32767 Inc = ZP177.6–...
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Parameters 177.175 P actual value sensor 1 -32768 to +32767 Pressure actual value of Sensor 1. Hardware-connection to input 1 of standard analog IO (connector X6) or input 3 of add- on module SVP. The active sensor for pressure control can be selected via bit 7 of control word SP 1 (ZP177.3–).
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Parameter description 177.194 Actuating variable 4 DS-support DINT 0 to 32767 Control difference of the adaption point 1. Scaling: 32767 Inc = ZP177.6– ZP177.7– 177.195 P-gain 0 DS-support DINT 0 to 65535 P-gain 0 (control difference < actuating variable 1). Scaling: 100:1 177.196...
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Parameters 177.200 Integral-action time 0 DS-support DINT 0 to 7200000 ms Integral-action time 0 (Control difference < Actuating variable 1). 177.201 Integral-action time 1 DS-support DINT 0 to 7200000 ms Integral-action time 1 (Control difference >Actuating variable 1 AND Control difference <...
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Parameter description 177.207 Ramp down time pressure set value DS-support DINT 0 to 4096 ms Ramp down time for pressure ramp function generator of set values. Ramp down time is related to a change from maximum pressure to 0 Bar. 177.228 Active Data Set...
Index Accept operator’s control P actual value Activate servo pump Pressure sensor inputs Adaptation Pressure set value Pump protection PWM frequency Caution Commissioning Copyright Ramp Customer service Reserved bits Reset errors Danger Dataset switching Save all DC link voltage Scaling Device data Signal processing 12, 13...
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Index Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH of 76...
Table of Figures Table of Figures Servo pump V1: General......................Servo pump V1: Adaption ......................Servo pump V1: Set/actual values ..................... Servo pump V1: Pump protection ....................Set values via field bus ......................Set values via analog inputs ...................... Pressure actual values via add-on module SVP ................ Pressure actual values without using an add-on module SVP...........
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Table of Figures Guided commissioning: Check scaling pressure set value............Guided commissioning: Sensor input ..................Guided commissioning: Scaling pressure actual value .............. Guided commissioning: Check scaling pressure actual value............ Guided commissioning: Setting the pressure control ..............Guided commissioning: Setting pump protection ............... Guided commissioning: Operator control ...................
Revision Survey Version Status Changes 5.17002.01 15-Feb-2017 First edition Servo pump V1.3 5.17002.02 3-May-2018 Error messages added Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 of 76...
Notes Application handbook Servo pump function V1 for BM5000 Document No.: 5.17002.02 Baumüller Nürnberg GmbH of 76...
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Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg T: +49(0)911-5432-0 F: +49(0)911-5432-130 www.baumueller.de All information given in this handbook is customer information, subject to change without notice. We reserve the right to futher develop and actualize our products continuously using our permanent revision service. Please notice, that specifications/data/information are current values according to the printing date. These statements are not legally binding according to the measurement, computation and calculations.
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