Baumuller BM4400 Series Modules BM4413-ST0-01600-03-SET

Technical Dossier

Product Details And Specifications

Baumuller BM4400 Series Technical Notes

The Baumuller BM4400 series represents one of the most widely deployed AC servo drive platforms in global heavy industry. Installed across chemical processing plants, nuclear power auxiliary systems, petroleum refineries, paper mills, and steel rolling lines, the BM4400 family provides closed-loop vector control for synchronous and asynchronous servo motors. Its modular architecture — separating the control board, power stage, and feedback interface — made it the reference design for multi-axis coordinated motion in European industrial automation from the mid-1990s through the 2010s. The BM4413-ST0-01600-03-SET is a specific controller drive configuration within this family, rated for 16A continuous output current, representing the mid-range power tier of the BM4413 sub-series.

The Evolution of BM4400 Architecture

The BM4400 series was introduced by Baumuller (Baumüller Nürnberg GmbH) as a successor to the earlier BM3000 and BM4200 drive families. The initial BM4400 variants used analog reference interfaces and resolver-based feedback, with DSP control boards operating at fixed switching frequencies. As the platform matured through successive hardware revisions, digital encoder interfaces (EnDat 2.1, SSI, Hiperface) were integrated, and the communication stack expanded to include PROFIBUS-DP, CANopen, and later PROFINET IO via plug-in communication modules. The BM4413 sub-series specifically targets single-axis servo applications with integrated braking chopper circuits. Compatibility between hardware generations requires careful attention to firmware revision levels: control boards from revision C onward are not backward-compatible with first-generation power stages without a firmware bridge adapter. Plants operating mixed-generation BM4400 installations must maintain a documented revision matrix to avoid commissioning failures during spare part substitution.

BM4400 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly stocked models within the Baumuller BM4400 series, organized by functional category:

Controller / Servo Drive Modules

• BM4413-ST0-01600-03-SET: Single-axis AC servo drive, 16A continuous, integrated braking chopper, SET configuration bundle
• BM4413-ST0-00600-03: Single-axis AC servo drive, 6A continuous output, standard power stage, resolver/encoder input
• BM4413-ST0-01000-03: Single-axis AC servo drive, 10A continuous, mid-range torque applications, DIN rail mount
• BM4413-ST0-02400-03: Single-axis AC servo drive, 24A continuous, high-dynamic servo axis, integrated DC bus connection
• BM4413-ST0-03200-03: Single-axis AC servo drive, 32A continuous, heavy-duty spindle and feed axis control
• BM4423-ST0-01600-03: Dual-axis AC servo drive, 16A per axis, shared DC bus, compact footprint for multi-axis cabinets
• BM4423-ST0-02400-03: Dual-axis AC servo drive, 24A per axis, coordinated motion control, PROFIBUS-DP ready
• BM4433-ST0-01600-03: Three-axis servo drive module, 16A per axis, synchronized multi-axis applications

Power Supply / Regenerative Feed Modules

• BM4450-ST0-00000-01: Active infeed/regenerative supply unit, 45kW, sinusoidal current draw, DC bus stabilization
• BM4452-ST0-00000-01: Active infeed module, 75kW, line regeneration capability, harmonic filter integrated
• BM4460-ST0-00000-01: Passive rectifier supply, 30kW, non-regenerative, cost-optimized installations

Communication & Option Modules

• BM4-O-PDP-01: PROFIBUS-DP slave communication module, plug-in format, compatible with BM4413/BM4423 control boards
• BM4-O-CAN-01: CANopen DS402 communication module, 1Mbit/s, plug-in format for BM4400 control boards
• BM4-O-ETH-01: PROFINET IO device module, 100Mbit, real-time class 1 and 2, IRT capable

Feedback & Encoder Interface Modules

• BM4-O-ENC-01: Incremental encoder interface, 5V TTL/RS422, A/B/Z channels, max 1MHz input frequency
• BM4-O-RES-01: Resolver interface module, 2-pole to 16-pole resolver support, 10kHz excitation frequency
• BM4-O-END-01: EnDat 2.1/2.2 absolute encoder interface, single-turn and multi-turn, plug-in format

Sourcing Hard-to-Find & Obsolete BM4400 Parts

The BM4400 series entered end-of-life status for new production in the early 2020s, with Baumuller transitioning its installed base toward the b maXX 5000 and b maXX 4400 successor platforms. However, the installed base of BM4400 drives in continuous operation at refineries, power stations, and process plants remains substantial. Replacement with successor platforms requires full re-engineering of the motion control application, which is cost-prohibitive for many facilities operating under long maintenance cycles.

Quality Control for the BM4400 Range

The BM4400 series uses a multi-layer backplane bus for inter-board communication between the control board, power interface board, and option modules. Failure modes specific to this architecture include backplane connector oxidation, DSP clock drift after capacitor aging, and IGBT gate driver degradation in high-cycle applications. DriveKNMS applies the following test protocol to all BM4400 units prior to dispatch:

• Visual inspection of PCB for corrosion, burn marks, and mechanical damage to connectors and bus bars
• DC bus capacitance measurement and ESR testing against OEM specification tolerances
• Power-on functional test under controlled load: current loop response, speed loop bandwidth verification
• Encoder and resolver interface signal integrity check across all supported feedback types
• Communication module handshake test (PROFIBUS, CANopen, or PROFINET as applicable)
• Thermal imaging under 75% rated load for minimum 30 minutes to identify latent hot spots
• Final firmware version documentation and revision label affixed to unit