SINUMERIK 840D SIMODRIVE 611 digital - Siemens AG · SINUMERIK 840D SIMODRIVE 611 digital Description of Functions 04.2000 Edition HLA Module Manufacturer/Service Documentation

SINUMERIK 840DSIMODRIVE 611 digital

Description of Functions 04.2000 Edition

HLA Module

Manufacturer/Service Documentation

SINUMERIK

840D/810D/FM-NC

SINUMERIK

Overview of SINUMERIK 840D/840Di/810D/FM-NC Documentation (04.00)

Brochure CatalogOrdering InfoNC 60.1 *)Technical Info.NC 60.2

Description ofFunctionsDrive Functions *)

Description ofFunctions-- Basic Machine *)-- Extended Functions-- Special Functions

SINUMERIK

611D840D/810D

SINUMERIK

840D/840Di/810D/FM-NC

840D/840Di/810D/FM-NC/611

Accessories

CatalogAccessories NC-Z

SINUMERIKSIROTECSIMODRIVE

840D/840Di/810DFM-NC611D

Lists *)Installation &Start-up Guide *)-- FM-NC-- 810D-- 840D/611D-- MMC

SINUMERIK

840D

Description ofFunctionsDigitizing

SINUMERIK

SINUMERIK

840D/810D/FM-NC

Configuring KitMMC 100/101-- ConfiguringSyntax

-- Development Kit

SINUMERIK

840D/810D/FM-NC

Screen KitMMC 100/101SWUpdateandConfiguration

SINUMERIK

840D/840Di/810D/FM-NC

SINUMERIK

840D/840Di/810D

OperatorComponents(HW) *)

840D/840Di/810D/FM-NC

Description ofFunctionsSINUMERIKSafety Integrated

SINUMERIKSIMODRIVE

SINUMERIK

840D/810D/FM-NC611,Motors

SIMODRIVE

DOC ON CD *)The SINUMERIK System

General Documentation

Electronic Documentation

Manufacturer / Service Documentation


SINUMERIK

840D/810D/FM-NC

SINUMERIK

840D/810D

User Documentation

DiagnosticsGuide *)

Operator’s Guide-- UnitOperator Panel

-- HPU-- HT 6

AutoTurn-- Short Guide-- Programming (1)-- Setup (2)

SINUMERIK

840D/840Di/810D/FM-NC

Program. Guide-- Short Guide-- Fundamentals *)-- Advanced *)-- Cycles-- Measuring Cycles

Description ofFunctions--ManualTurn-- ShopMill

Description ofFunctionsSynchronizedActionsWood, Glass,Ceramics

840D/810D

SINUMERIK

Operator’s Guide--ManualTurn-- Short Guide ManualTurn-- ShopMill-- Short Guide ShopMill

840D/810D


SINUMERIK

840D/810D

Descr. of Functions-- Computer Link-- Tool DataInformationSystem

*) These documents are a minimum requirement for the control

Operator’s Guide-- Short Guide-- Operator’sGuide *)

SINUMERIK

840D/810D/FM-NC

Configuring(HW) *)-- FM-NC-- 810D-- 840D

SINUMERIK

SINUMERIK

840D/810D

SINUMERIK

840D/810D/FM-NC

Description ofFunctionsOperator InterfaceOP 030

Description ofFunctionsTool Manage-ment

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

840D611D

840D611D

Description ofFunctionsLinear Motor

SINUMERIKSIMODRIVESIROTEC

EMCGuidelines

Description ofFunctions-- HydraulicsModule

-- Analog Module

User Documentation

SINUMERIK

System Overview

840Di


SINUMERIK

Descr. of FunctionsISO Dialects forSINUMERIK

840D/810D

SINUMERIK

Descr. of FunctionsCAM IntegrationDNC NT-2000

SINUMERIK

Manual(HW+ Installationand Start-up)

840Di

Valid for

Control Software versionSINUMERIK 840D 5SINUMERIK 840DE (export version) 5

04.00 Edition

SINUMERIK 840DSIMODRIVE 611 digital

HLA module

Description of Functions

General 1

Configuring 2

Start-Up 3

Firmware DriveFunctions 4

Hardware DriveFunctions 5

Hydraulics Diagnostics 6

Peripherals/Accessories 7

Service 8

Hydraulics A

Abbreviations B

Definition of Terms C

References D

EC Declaration of Conformity E

Index F

SINUMERIK Documentation

Printing history

Brief details of this edition and previous editions are listed below.

The status of each edition is shown by the code in the ”Remarks” column.

Status code in the ”Remarks” column:

A New documentation.. . . . . B Unrevised reprint with new Order No.. . . . . C Revised edition with new status. . . . . .

If factual changes have been made on the page in relation to the same softwareversion, this indicated by a new edition coding in the header on that page.

Edition Order No. Remarks02.99 6SN1197–0AB60–0BP0 A08.99 6SN1197–0AB60–0BP1 C04.00 6SN1197–0AB60–0BP2 C

This manual is included in the documentation on CD-ROM (DOCONCD)Edition Order No. Remarks04.00 6FC5 298–5CA00–0BG2

TrademarksSIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIK und SIMODRIVE sind Marken vonSiemens. Other names in this publication might be trademarks whose use by a third party for his ownpurposes may violate the rights of the registered holder.

Further information is available on the Internet under:http://www.ad.siemens.de/sinumerik

This publication was produced with Interleaf V 7.0.

The reproduction, transmission or use of this document or itscontents is not permitted without express written authority. Offenderswill be liable for damages. All rights, including created by patent grantor registration of a utility model or design, are reserved.

Siemens AG 2000. All rights reserved

Other functions not described in this documentation might beexecutable in the control. However, no claim can be made regardingthe availability of these functions when the equipment is first suppliedor for service cases.

We have checked that the contents of this document correspond tothe hardware and software described. Nonetheless, differences mightexist and therefore we cannot guarantee that they are completelyidentical. The information contained in this document is, however,reviewed regularly and any necessary changes will be included in thenext edition. We welcome suggestions for improvement.

Subject to changes without prior notice.

Siemens AktiengesellschaftOrder No. 6SN1197–0AB60–0BP1Printed in the Federal Republic of Germany

3ls

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User information

The documentation for SIMODRIVE 611/SINUMERIK 840D is organized on thefollowing levels:

General documentation

Manufacturer/service documentation

Electronic documentation

The Description of Functions of the HLD module is part of the SIMODRIVE/SINUMERIK range of documentation.

For further information about the publications listed in the documentation over-view and other available SIMODRIVE/SINUMERIK publications, please contactyour local Siemens sales office.

This Description of Functions does not purport to cover all details or variationsin equipment, nor to provide for every possible contingency to be met in con-nection with installation, operation or maintenance.

The contents of this document shall neither become part of nor modify any prioror existing agreement, commitment or relationship. The Sales Contract containsthe entire obligations of Siemens. The warranty contained in the contract be-tween the parties is the sole warranty of Siemens. Any statements containedherein do not create new warranties or modify the existing warranty.

This documentation is intended for use by machine manufacturers and servicing personnel who use “HLD modules”.

This Description of Functions provides the information required to configure andstart up the hydraulic drive module.

Chapter 2 describes the procedures to be followed to configure electricaland hydraulic components.

Chapter 3 shows how the hydraulic drive is started up with the support of amenu-assisted interface.

Functionalities provided by the firmware and the HLD module hardware areexplained in Chapters 4 and 5.

Chapter 6 explains how to check and interpret status displays and alarms(hydraulics diagnostics).

Chapter 7 describes the accessories required, such as measuring systemand cables.

Appendix A contains general information and an explanation of hydraulicsystem functionalities.

Note

Hydraulics

Information about special hydraulics functions mentioned in this document referto functions supplied by Bosch.

Preface

Structure of thedocumentation

Target group

Aim

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Should further information be desired or should particular problems arise whichare not covered sufficiently for the purchaser’s purposes, the matter should bereferred to the local Siemens Sales Office.

The following guide information is provided to help you reference information inthis Description of Functions:

General table of contents

Header (as orientation aid):

– The top line of the header is the main section number

– The second line of the header is the subsection number

Appendix with

– abbreviations, terms and references

– glossary (index)

If you require further explanation of a particular term, function or opera-tion, you will find references to pages containing further relevant informa-tion in the glossary.

For the purpose of this Description of Functions and product labels, a “qualifiedperson” is one who is familiar with the installation, mounting, start-up and opera-tion of the equipment and the hazards involved. He or she must have the follow-ing qualifications

Trained and authorized to energize, de-energize, ground and tag circuitsand equipment in accordance with established safety procedures.

Trained in the proper care and use of protective equipment in accordancewith established safety procedures.

Trained in rendering first aid.

The SW versions specified in this documentation refer to the SINUMERIK 840Dcontrol system and the HLD module.

The Description of Functions applies only to the software versions specified.When a new software version is released, the Description of Functions for thatversion must be ordered.

!Important

This documentation applies to:

SINUMERIK 840D control and SIMODRIVE 611 digital drive system, software version 5

How to use thismanual

Definition: How is a qualifiedperson defined?

Softwareversions

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!Important

This symbol always appears in the documentation when important informationis being conveyed.

Order data option

In this documentation, you will find this symbol with a reference to an orderingoption. The function described is executable only if the control contains thedesignated option.

Machine manufacturer

This symbol appears in this documentation whenever the machine manufac-turer can influence or modify the described functional behavior. Please observethe information provided by the machine manufacturer.

!Danger

This symbol appears whenever death, severe physical injury or substantialmaterial damage will occur if the appropriate precautions are not taken.

!Caution

This symbol appears whenever minor physical injury or material damage mayoccur if the appropriate precautions are not taken.

!Warning

This symbol appears whenever death, severe physical injury or substantialmaterial damage may occur if the appropriate precautions are not taken.

Explanation ofsymbols

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viii Siemens AG 2000. All rights reserved


Technical information

!Warning

Operational electrical equipment has parts and components which are at haz-ardous voltage levels.

Incorrect handling of these units, i.e. not observing the warning information, cantherefore result in severe bodily injury or property damage.

Only appropriately qualified personnel may commission/start-up this equip-ment.

This personnel must be thoroughly familiar with all the warning information andservice instructions given in this Description.

Perfect and safe operation of this equipment assumes professional transport,storage, mounting and installation as well as careful operator control and ser-vicing.

Hazardous axis motion can occur when working with the equipment.

Note

When handling cables, please observe the following:

They must not be damaged

They must not be stressed

They must not come into contact with rotating components.

!Warning

Before the plant voltage test on the electrical components of machinery is car-ried out, all terminals on the SIMODRIVE device must be disconnected (EN 60204-1 (VDE0113-1), para. 20.4).

This is necessary to avoid subjecting pre-tested isolation on the SIMODRIVE equipment to any unnecessary additional stresses.

!Warning

Start-up/commissioning is absolutely prohibited until it has been ensured thatthe machine, in which the components described here are to be installed, fulfillsthe regulations/specifications of Machinery Directive 89/392/EEC.

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!Warning

The information and instructions in all the documentation supplied and anyother instructions must always be observed to eliminate hazardous situationsand damage.

The information given in catalogs and quotations applies additionally tospecial versions of machines and equipment.

Furthermore, all relevant national, local and plant-specific regulations andspecifications must also be taken into account.

All work must be undertaken with the system in a no-voltage condition(powered down!)

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Components which can be destroyed by Electro Static Discharge

Components which can be destroyed by electrostatic discharge are individualcomponents, integrated circuits or boards which, when handled, tested ortransported, could be destroyed by electrostatic fields or electrostatic dis-charge. These components are designated as ESDS (ElectroStatic DischargeSensitive Devices).Handling ESDS boards:

When handling components which can be destroyed by electrostatic di-scharge, it must be ensured that personnel, the workstation and packagingare well grounded,.

As a general rule, electronic boards should only be touched when absolu-tely necessary.

You may only touch ESDS components if

– you are continuously grounded via an ESDS bracelet,

– you are wearing ESDS shoes or ESDS shoe grounding strips in con-junction with an ESDS floor surface.

Boards may only be placed on conductive surfaces (desk with ESDS sur-face, conductive ESDS foam rubber, ESDS packing bag, ESDS transportcontainers).

Boards may not be brought close to data terminals, monitors or televisionsets (a minimum of 10 cm should be kept between the board and thescreen).

Boards may not be brought into contact with materials which can be char-ged and are highly insulating,e.g. plastic foils, insulating desktops, articles of clothing manufactured fromman-made fibers.

Measurements may be taken on the boards only if

– the measuring equipment is grounded (e.g. via the protective conductor)or

– in the case of floating measuring instruments, the probe is briefly dis-charged before a measurement is taken (e.g. through contact with barecontrol housing).

Closed-loop control modules, option modules and memory submodulesmay only be held by the front plate or on the board edges.

ESDS instructions

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Edition

Contents

1 General 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Examples of applications 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Comparison of electrical and hydraulic drive systems 1-16. . . . . . . . . .

1.3 Construction of an electro-hydraulically controlled drive axis 1-18. . . . 1.3.1 Machine guideway 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2 Cylinders 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3 Servo solenoid valve 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.4 Valve amplifier 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.5 Shutoff valve 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.6 Position measuring system 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital 1-20. . . . . . . . . . . . . . . . . . . 1.3.8 Hydraulic power unit 1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Configuring 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Configuring steps 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Procedure for configuring electrical components 2-21. . . . . . . . . . . . . . . 2.1.2 Procedure for configuring hydraulic components 2-22. . . . . . . . . . . . . . .

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital 2-24. . . . . . . 2.2.1 System overview 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Required FW packages 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Hardware requirements 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Configuring the hydraulic drive 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Cylinder selection 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Selection of servo solenoid valves 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Selection of shutoff valves 2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Natural frequency of hydraulic drive 2-42. . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5 Hydraulic power unit 2-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Wiring 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1 Internal power supply 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2 External power supply 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3 Earthing system/electromagnetic compatibility (EMC) 2-49. . . . . . . . . .

3 Start-Up 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Overview of start-up process 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Drive configuration 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Drive machine data 3-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Valve selection 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 General 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Cylinder selection 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Mounting/supply data 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Measuring system data 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Changing data 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.9 Fine adjustment and optimization 3-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Control direction, travel direction 3-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 Offset adjustment 3-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.3 Velocity compensation 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.4 Referencing data for HLA 3-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.5 Controller optimization 3-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.6 Controller adaptation 3-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.7 Hydraulic/electrical interpolation 3-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 File functions 3-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 Start-up functions 3-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.1 Measurement function 3-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2 Function generator 3-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.3 Circularity test 3-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.4 Servo trace 3-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.5 DAC parameterization 3-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 User views 3-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13 Display options 3-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14 Configuring an OEM valve list 3-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Firmware Drive Functions 4-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Block diagram of closed-loop control 4-97. . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Functions 4-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Overview of functions 4-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 System environment 4-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Closed-loop velocity control 4-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Velocity adaptation/feedforward control 4-100. . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Velocity controller 4-107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Dynamic Stiffness Control (DSC) 4-115. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Closed-loop force control 4-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Force limitation 4-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Static friction injection 4-119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3 Force controller 4-120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Output of manipulated variables 4-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Characteristics compensation 4-125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.2 Control output filter 4-130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.3 Manipulated voltage limitation 4-132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Supply unit data 4-133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Valve 4-134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Cylinder drive 4-136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Drive data 4-137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 Position measuring system 4-140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11 Pressure sensors 4-143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12 Terminals 4-144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13 Monitoring functions 4-150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13.1 Alarms 4-150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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xiii Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00

Edition

4.13.2 Variable signalling functions 4-152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14 Service functions 4-157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.1 Min/max display 4-157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.2 Monitor 4-158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.3 Diagnostic machine data 4-159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15 Table of parameters 4-163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Hardware Drive Functions 5-173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Overview of interfaces 5-174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Measuring system 5-176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Pressure sensors 5-177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3 Servo solenoid valve 5-178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4 Terminals 5-179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.5 Test sockets (diagnosis) 5-180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.6 Bus interfaces 5-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 System environment 5-182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Additional information 5-183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Climatic and mechanical environmental conditions in operation 5-183. . 5.3.2 Shipment and storage conditions 5-184. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Resistance to pollutants 5-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Hydraulics Diagnostics 6-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Peripherals/Accessories 7-215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Measuring systems 7-215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Encoders, linear scales 7-215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Connection diagrams 7-218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 BERO (X432) 7-221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Pressure sensing 7-222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1 Sensors 7-222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2 Connection diagrams 7-226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Connection diagrams for servo solenoid valves 7-227. . . . . . . . . . . . . . . .

8 Service 8-231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Areas of responsibility of Siemens and Bosch 8-231. . . . . . . . . . . . . . . . .

8.2 Hotline 8-232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Hydraulics A-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Servo solenoid valves A-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1 General A-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.2 Servo solenoid valves of sizes 6 and 10 A-242. . . . . . . . . . . . . . . . . . . . . . A.1.3 Pilot-actuated sizes 10 and 16 servo solenoid valves A-244. . . . . . . . . . . A.1.4 HRV valves A-247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Cylinder A-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04.00

02.99

xiv Siemens AG 2000. All rights reserved


B Abbreviations B-251. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C Definition of Terms C-255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D References D-257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.1 Electrical applications D-257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.2 Hydraulic applications D-266. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E EC Declaration of Conformity E-267. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F Index Index-271. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

04.00

1-15 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

General

1.1 Examples of applications

The NCU 573.2 of the SINUMERIK 840D is capable of handling axis configurations of a maximum of 31 axes in up to 10 different channels. Thisfunctional sophistication makes the SINUMERIK 840D an increasingly popularsystem for the automation of rotary indexing machines. These machines areoften highly compact in design and frequently equipped with hydraulic axes(cylinders and servo solenoid valves). The hydraulics (HLA) module provides ameans of controlling hydraulic axes directly from the SINUMERIK 840D systemvia the digital drive bus.

The HLA module is a closed-loop control plug-in unit of the modular SIMO-DRIVE 611 converter system mounted in a 50 mm carrier module (universalempty housing).

The gating and closed-loop control electronics for operating hydraulic drives areintegrated on the HLA module.

From the point of view of the manufacturer of modern servo solenoid valves, aninnovative step in the field of hydraulic drive systems has been taken by treatingelectrical and hydraulic drives as “equal partners” and integrating them into astandard NC.

To place equal emphasis on the functional importance of both hydraulic andelectrical drives and make them available as a combined system within an inter-polating axis grouping.

Firmware

The communications interface is compatible with the SIMODRIVE 611DSRM(FDD)/ARM(MSD) for supported services. Code and data managementis analogous to the SIMODRIVE 611D SRM(FDD)/ARM(MSD). The hydrau-lics software is stored as a separate program code in the control system.

Hardware

The mode of integration into the SIMODRIVE 611 system is compatible with the SIMODRIVE 611 digital SRM(FDD)/ARM(MSD). This basically involvesthe following interfaces:

– Drive bus

– Device bus

– Power supply system

Examples of applications

Objective

Interfaces

1

02.99

1-16 Siemens AG 2000. All rights reserved


1.2 Comparison of electrical and hydraulic drive systems

Table 1-1 Comparison of electrical and hydraulic drive systems

Criterion Electrical direct drive Electrical drive with leadscrew

Hydraulic drive

Power density /mountingspace require-ments

Electrical part onmachine table

is light and requireslittle space.

Servomotor and lead-screw large andheavy.

Problematic with lim-ited mounting space.

Cylinder and servo sole-noid valve are light-weightand compact.

Transfer of E motor tohydraulic power unit.

Mass inertia ofmoving parts

Electrical part onmachine table has lowmass.

Servomotor and lead-screw have high massmoment of inertia.

Piston and piston rod havevery low mass

Operationalreliability, ser-vice life

Service life depends in principle only on linearguides.

Shock-sensitive.

Service life limited byleadscrew.

Sudden failure possible.

Protected against overloadby pressure limitation.

Sturdy, insensitive toshocks.

Cylinder seals and valvecontrol edges have longservice life.

Warning of wear.

Servicing Simple replacement Expensive replacementand repair of leadscrew byspecialists.

Simple error diagnosis

Simple replacement andrepair of valves and cylin-ders.

Energy storage Peak requirement mustbe installed as no storagepossible.

Peak requirement must beinstalled as no storagepossible.

Compensation of energyrequirement peaks by hy-draulic accumulator.

Rapid traverse in differen-tial circuit.

Reduction of installed ca-pacity.

Maximumforces

Peak thrust per unit areaapprox. 40 to 80 kN/m2

Restriction with largerforces.

Practically unlimited (6MN)(Cylinder φ, pmax=315 bar)

Load stiffness Very good;Servo gain can be set tobetw. 10–100 timeshigher than on the othertwo drives.

Elasticity under largeforces.

Elasticity of leadscrewis largely compen-sated as a controlfunction.

Oil compressibility is com-pensated as a controlfunction (I component).

Good zero overlap qualityof valve ensures very highrigidity under load.

Maximumvelocity

Up to 500 m/min vmax=hs ωmax/2πhs=thread leadωmax=max. motor speed

120 m/min with standard servo-cylinder

Maximumtravel path

Unlimited 6 m 1 m

Collision protection

Mechanically difficult Mechanically possible Mechanically possible

1 General


02.99


Table 1-1 Comparison of electrical and hydraulic drive systems

Criterion Hydraulic driveElectrical drive with leadscrew

Electrical direct drive

Noise Noise produced by linear guides

Noise produced by servo-motor and leadscrew

Flow through valve mayproduce noise.

Pump noise on hydraulic power unit.

Accelerationcharacteristics

Max. 45 g Max. 1 g Max. 2 g

Drive cooling Mandatory Required only at highspeeds

Required in some cases, inpower unit only

Sensitivity toferromagneticswarf

High Low Low

Table 1-2 Analogy of characteristic data

Electrical Hydraulic

Speed –

Speed Speed

Current flow

DC link voltage System pressure

Power Flowrate Valve pressure difference

Transistor/power section Valve

motor Drive cylinder

1 General


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1.3 Construction of an electro-hydraulically controlled driveaxis

SINUMERIK 840D, SIMODRIVE 611 digitalwith HLA module Servo solenoid value with

valve amplifier (OBE)

Machine guideway

Position measuringsystemHydraulic power unit

Shutoff valve

Fig. 1-1 Construction of an electro-hydraulically controlled drive axis

1.3.1 Machine guideway

Hydrodynamic and hydrostatic sliding or roller guides allow rectilinear motion of machine slides and tables to take place with minimum friction and maximumprecision.

A certain degree of friction can be very useful for the purpose of damping os-cillations.

However, excessive friction, especially pronounced transitions from static tosliding friction, have a negative effect on the control result and impair the controlloop stability.

Guide mechanism

Friction

1 General

1.3 Construction of an electro-hydraulically controlled drive axis

02.99


1.3.2 Cylinders

The cylinder represents the simplest form of linear motor and can be integratedeasily into the machine guide. The cylinder normally has a piston rod at oneend.

The following are critical quality criteria:

The surface quality of barrel and piston rod and

The seals and guides (low-friction, servo quality...).

1.3.3 Servo solenoid valve

This is the final control element in the closed control loop and forms the electro-hydraulic converter.

The valve steplessly converts electrical signals into a hydraulic flow.

Its quality is defined by static and dynamic parameters, such as

zero overlap

Hysteresis

limit frequency, etc.

definiert.

1.3.4 Valve amplifier

This circuit contains the power electronics for the solenoid in the servo solenoidvalve which adjusts the valve spool position.

The position controller in the valve amplifier (on-board electronics – OBE) con-trols the position of the valve spool proportionally to the manipulated variable(U=0...10 V).

1.3.5 Shutoff valve

Shutoff valves are intermediate plate valves, sizes 6 and 10, combined in mostcases with servo solenoid valves and HRVs. They perform safety functions bydisconnecting the system pressure from the servo solenoid valve(s).

1.3.6 Position measuring system

The position measuring system supplies the actual value for the position of themoving machine element.

Construction

Quality criteria

Task

Function

Task

1 General


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The speed is acquired through continuous differentiation of distance over time.Various systems are available depending on the level of accuracy required.

The highest accuracy requirements are fulfilled by digital systems (glass scalewith photoelectric evaluation circuit) mounted directly on the machine.

The most widely used digital incremental systems require a reference point ap-proach at the beginning of a machining operation.

1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital

SINUMERIK controls and SIMODRIVE drive systems are specially designed formachine tools, manipulators and special-purpose machines.

The numerical control processes the machine program and converts it into con-trol commands. It also monitors command execution continuously.

The control structures for the electrohydraulic control loop and the interfaces to

the shutoff valve,

the servo solenoid valve,

the position measuring system and

the central arithmetic logic unit

are all provided by the HLA module.

The HLA module is an integral component of the SINUMERIK 840D and SIMODRIVE 611 digital systems.

A range of different NCU modules with graded scope of functions is provided toallow the SINUMERIK 840D system to be tailored to the varying functional re-quirements of machines. The control can therefore be optimally adapted to indi-vidual machines and machining applications and is suitable for equipping stan-dardized machine series.

1.3.8 Hydraulic power unit

This unit supplies hydraulic energy.

It is installed at a distance from the drive axis. Accumulators are employed tocompensate for strongly fluctuating hydraulic energy requirements and to mini-mize the installed power.

Function

1 General



Configuring

2.1 Configuring steps

2.1.1 Procedure for configuring electrical components

The procedure for configuring an HLA module is divided into steps in such away that the user is guided through the full range of relevant settings, from therequired force, to the hydraulics components, and finally the HLA and its en-coder evaluation circuitry. This initial configuring phase may be followed by asecond in some cases, in which the corresponding circuit recommendationsand EMC measures are taken into account.

The functions of SIMODRIVE components are described with keywords in thisPlanning Guide. Limit values for functions may be specified in some cases. For further details (e.g. characteristics), please refer to the Installation andStart-Up Guides for SIMODRIVE 611D and SINUMERIK 840D.

Further configuring instructions and detailed ordering information can be foundin Catalogs NC 60 and NC Z.

and publication 6SN1197-0AA00

and Bosch publication

Section 2.2

Section 2.4

Selection of hydrau-lic components

Dimensioning of incom-ing mains supply

Dimensioning ofpower modules

Chapter 4Dimensioning ofclosed-loop control components

Dimensioning of positionsensor (measuring system)

Section 7.1

Dimensioning of exter-nal power supply

Section 2.3

and publication 6SN1197-0AA00

Section 2.2

Fig. 2-1 Configuring steps in start-up sequence

Phase 1

2

02.99



Abbreviations, terms and index

Section 2.4

Section 2.2

Appendix

Recommended circuitsEMC measures

Block diagrams/connection diagrams

Fig. 2-2 2nd configuring phase

2.1.2 Procedure for configuring hydraulic components

Hydraulically controlled drives are normally configured by the technical salesand marketing personnel of the hydraulics supplier (e.g. Bosch, see Chapter 8for contact address) in close co-operation with the machine manufacturer.

This configuring phase is divided into the following steps:

Selection of cylinder on the basis of required forces and velocities, and cylin-der mounting conditions in the machine (see Section 2.3.1).

Selection of servo solenoid valves on the basis of cylinder data, forces, ve-locities and dynamic requirements (see Section 2.3.2, 2.3.3).

Selection of position measuring system, plus pressure sensors in somecases, on the basis of measuring range, accuracy and linearity (see Section7.1, 7.3).

Dimensioning of hydraulic power unit, taking all loads into account (see Sec-tion 2.3.5).

Calculation of natural frequency of drive for initial assessment of whetherexpected control result can be achieved (see Section 2.3.4).

Bosch sales personnel are assisted by the “Hydro 2” hydraulic configurationcalculation program.

The basic data required to design a system are obtained from a question-naire.

Phase 2

2 Configuring


02.99


Design of hydraulic NC axes

Hydraulic NC axesDesign of systems with linear motions

Company:

Address:

Machine:

Contact person:

Department:

Telephone:

Axis: Function/designation:Straight-cut control: Continuous-path control:

Drive specification

Cylinder dimensions [mm]

Piston diameter:1 rod diameter:2nd rod diameter:Stroke:

Accuracy requirements

Positioning precision [mm]from rapid traverse:from feedrate:Path accuracy:

Cylinder mounting position: Velocitytolerance [mm/min]:

Connections: Position measuring systemValve – cylinder

Pipe/Hose length [mm]:

Pipe/Hose diameter [mm]:

Moved mass [kg]:

Machining forces [N]

Piston advance:

Max. delay:

Piston retraction:

Slide guide friction

m:

FR [N]:

Pump pressure [bar]:

Velocities [m/min]

Rapid traverse advance:

Rapid traverse retract:

Machining feed advance:

Machining feed retract:

Acceleration rates [m/s2]

Max. acceleration:

Processed by: Dept.: No. of pages: Date:

Make:

Type:

Other:

Resolution [mm]:

Numerical control

Make:

Type:

SIEMENS

840D

051–001/

output signal ...

incremental,

Questionnaire

2 Configuring


02.99



2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2.1 System overview

A complete 840D control system with HLA module consists of various individualcomponents. These are listed in the table below.

Table 2-1 Components of 840D with HLA module (number, component, description)

No. Component Description

A NCU box Enclosure for NC CPU

B NC CPU Central processing unit of 840D Execution of NC program, Contains modules with e.g. PLC, communications

functions NCU 573.2 includes a fan module

B1 Cable distributor For insertion in NCUC1) Operator panel Display, keyboard, power supply and NC

operating components

D1) MMC module Operator panel calculator (integrated in panel), MMC 103 with hard disk

E Mains infeed (NE) References: /PJ1/ SIMODRIVE 611F1) Machine control panel Machine operation

G11)

ISA adapter Allows AT modules to be used in conjunction withthe MMC module MMC103 (mounted in operatorpanel)

G21)

CNC full keyboard Full keyboard for connection to MMC module

G3 Memory card (PCMCIA) Contains the system program, can be slotted into the NCU 561.2, 571.2, 572.2,

573.2G4 Diskette unit (accessory) Built-in unit for connection to MMC moduleH1to H 9

Cables References: /Z/, Accessories Catalog NC Z

H10toH12

Cables See Section 7, Peripherals/Accessories

I SIMODRIVE hydraulicsmodule (HLA module)

Closed-loop control of hydraulic drive Actuation of servo solenoid valve

50 mm carrier module (uni-versal empty housing)

Holder for HLA closed-loop control plug-in module(see Fig. 2-6)

I1 Phoenix cable connection Shutoff valve External 24 V supply BERO input “power enable”

J SIMATIC components References: /S7H/, ManualK Terminator Terminator for drive bus (inserted in last module in

drive grouping)

Components

2 Configuring


02.99


Table 2-1 Components of 840D with HLA module (number, component, description)

No. Component Description

L1) Hand-held unit Connect HHU to K bus via MPI Handwheel, EMERGENCY STOP button, keys-

witch, override, enable keys, display, free keysM 1)

Distribution box For linking the hand-held unit to the MPI bus Connection for EMERGENCY STOP circuit, ena-

ble keys, handwheel, 24 V DCN Cable distributor 24 V supply for connection to MPI connectorO Hydraulic drive References: AKY o13/2; BEY 014/4; BEY 013/31P External 24 V supply SITOP stabilized power supply modules

References: Catalog SITOP powerOrder No. E80001-V0752-A253

1) A description of these components can be found in:

References: /BH/, Operator Components Manual

Note

An HLA module must never be operated directly on a SIMODRIVE monitoringmodule, i.e. it must be connected via a mains infeed module.

For information about connecting further additional SIMODRIVE monitoringmodules in configurations with several HLA modules, please refer to the SIMODRIVE 611 Planning Guide (/PJ1/).

In a multi-tier configuration, all incoming supply units must be switched in simul-taneously.

2 Configuring


02.99



MCP

Floppy

MMC CPU

Device bus

Battery and fan plug-in unit

HLAmodule

NCU

Digital I/O(high-speed NC I/O)

Handwheel(2x) (1x of M)

Measurement (2x)

S7-300

J

A

G3

B

F

G2

G1

G4

D

I

C

H1

H9

H4

H5

H6

B1

K

ÄÄÄÄ

M

H8

L

N

H3H2

Supply 26.5 V external

Enable signal

BERO inputs

I1

H12H11

H10

E

SITOP power(external PS)

PNote: Display of hydraulics for one axis

Servo solenoid

Pressure sensor A

Position sensor

Pressure sensor B

Shutoff valve

O

NE

valve

Fig. 2-3 System components

2 Configuring


02.99


C2B1

Axis 1

BERO input, axis 1

X11

41

X13

41

Position measur-

HLA

Device bus interface (X151)

–X11

1

–X11

2

–X12

1

–X12

2

Hydraulic drive, axis 1

Pressure sensor

Servo solenoid

–X10

1

–X10

2

Shutoff valve, axis 1

Supply 26.5 V external

Internal +24 V enabling voltage

Drive bus/drive bus terminatoron last module

–X34–X35

Shutoff valve, axis 2

BERO input, axis 2Power enable at term. 663Internal 0 V enabling voltage

Internal +24 V enabling voltage

Servo solenoid

Pressure sensor A

Hydraulic drive, axis 2

Position sensor

Pressure sensor B

Shutoff valve

Electronics ground

Reserved, do not use!

Electronic ground1)

Reserved, do not use!

Position measuring

Pressure sensor

Servo solenoid

Servo solenoid

Pressure sensor A

Position sensor

Pressure sensor B

Shutoff valve

Axis 2

Drive bus

+–+–

+–

X431 X432

A

B

A

B

A

B

A

B

A

B

PV1

C1

M24P24

M

MV1

6639

PV2

19

M

MV2

B29

1) Only required if external 26.5 V is not electrically separated safely!

system

valve

valve valve

ing system

valve

Fig. 2-4 Connection configuration for HLA module

2 Configuring


02.99



M600

P600

X351

X111

X121

X141

X161

X171

X172

X181

U1 V1 W1 X131 PE

red

yellow

red

5V voltage level faulty

Device ready(DC link precharged)

DC linkovervoltage

Electronics powersupply faulty

Device is not ready,enable signal (term. 63, 64 or 48) missing

Mains fault

Mains connection

Devicebus

DC link connection

red

green

red

LEDdisplays

5.35.25.163

99

6419

74

73.173.2

72

7454410

1515

R

911248111

113

NS2NS1

AS2AS1

Relay contact for Ready signal

NC contact

NO contact

Relay contact for group signal I2t and mo-tor overtemperature

Power disableEnable voltage

Drive enable signalReference potential for enable voltage

Enable voltage

P24P15N15N24MMRESET (R+term.15)

Enable voltageSetup modeEnergize contactor, start

213Line contactor signalling con-tact

Enable signal for internal line con-tactor

Starting disable signalling contact(NC)

M500

P5002U11U12V11V12W1

1W1

DC link power supply for bridgingpower failures

Electronics power supply from external sourceElectronics power supply from external source

Electronics power supply from external source

1)

1)

1) Jumpers inserted in delivery state

LED displays

1)

Fig. 2-5 NE module interfaces (UE and I/R modules)

2 Configuring


02.99


50 mm carrier module(universal empty housing)(6SN1162-1AA00-0AA0)

Rating plate/Order No.

Order No.

HLA closed-loop controlplug-in module(6SN1115-0BA11-0AA0)

M3 / 0.8 Nm

M4 / 1.8 Nm

M3 / 0.8 Nm

P600

M600

PE

M5 / 3.0 Nm

Shield connection

Slotted screw

Slotted screw

Fig. 2-6 Mounting the HLA closed-loop control plug-in module in 50 mm carrier module (universal empty housing)

2.2.2 Required FW packages

SINUMERIK 840D NCK SW 5.1 incl. SIMODRIVE 611 digital HLA Module 1.0

SINUMERIK 840D MMC SW 5.1

2.2.3 Hardware requirements

NCU 561.2, 571.2, 572.2, 573.2

Mounting the HLAclosed-loop controlplug-in module

2 Configuring


04.00

02.99



2.3 Configuring the hydraulic drive

Hydraulic drives are generally configured by technical sales and marketing per-sonnel from hydraulics supplier Bosch. Bosch personnel are supported by the“HYDRO 2” calculation program (for internal use only). The data supplied by thecustomer on the questionnaire described in Section 2.1.2 serve as initial dimen-sioning information.

Please refer to Appendix A for a description of hydraulic components.

The hydraulic drive is configured in the sequence of steps described below.

2.3.1 Cylinder selection

The piston and rod diameters are calculated according to Pascal’s theorem (seebelow) on the basis of the necessary pressure and tensile forces F and a stan-dard pressure value of P=40...100 bar for machine tools (a maximum pressuresetting of 350 bar is permitted).

p = FA

The force value calculation must include friction and acceleration forcesas well as the actual feed force. Pistons and rods with the following standarddiameter dimensions are available:

Table 2-2 Typical cylinder data

Designation Diameter

Piston ∅ 25 32 40 50 63 80 100 125

Rod ∅ Standard 12 14 18 22 28 36 45 56

Rod ∅ Optional 18 22 28 36 45 56 70 90

The stroke is identical to the working stroke of the drive, with some additionalsafety reserves.

General

Piston and roddiameter

Stroke length

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In the interest of obtaining high control quality, the cylinder must be mounted bya backlash-free method, such as flange or base mounting.

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

Base mounting

Flange mounting

Flange at front Flange at rearÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌ

Fig. 2-7 Cylinder mounting methods

This is dependent on the machine situation and affects the selection of shutoffvalves (see Section 2.3.3). Vertical loads must be protected via poppet valves.Forces due to weight must be taken into account in the final calculation of theoperating pressure (MD 5151: CYLINDER_A_ORIENTATION).

Fig. 2-8 Cylinder mounting position

Low friction can be maintained by using suitable seals. Transitions from static tosliding friction have a particularly adverse affect on the control result.

The slide guide friction must be added to the cylinder friction. A friction com-pensation function can be activated in the HLA module (MD 5460:FRIC-TION_COMP_RADIENT) in order to overcome initial friction.

The distance between the cylinder and servo solenoid valve must be kept asshort as possible for the sake of the frequency (compressibility of oil volume). Inideal cases, the servo solenoid valve is flange-mounted directly on the cylinder.

The incremental and absolute position measuring systems supported by theHLA module are mounted on the machine slide. The HLA module does not sup-port cylinder-integrated position measuring systems (magnetostrictive or poten-tiometer).

Mounting

Mounting position

Seal, Friction

Cylinder pipes

Position measuring system

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2.3.2 Selection of servo solenoid valvesReferences: Bosch AKY 013/2

The HLA module supports Bosch servo solenoid valves with integrated (OBE)electronics, for which technical data are stored in the software of the module, aswell as valves supplied by other manufacturers. The drive is parameterized au-tomatically when the order number is entered. The following table shows anoverview of the servo solenoid valves supplied by Bosch.

For a complete list, please see Tables 2-5 to 2-11.Table 2-3 Valve types

Name Nomi-nalsize

Volumetric flowQnom (l/min at∆p

(bar)

Character-istic

Limit fre-quency 1)

(Hz)

Directly actuated servo solenoid valve

Size 6 up to 40 / 35 bar linear andwith knee

110

Size10

up to 100 / 35 bar linear andwith knee

85

Pilot-actuated servo solenoid valve

Size10

up to 70 / 5 bar with knee 40

Size16


High Response Valve (HRV1)

Size 6 up to 40 / 35 bar linear andwith knee

210

High Response Valve (HRV2)

Size10


Size16


1) The characteristic values for the servo solenoid valve limited frequencies stated in table 2-3 refer to an amplitude of 5% and a phase offset in the Bode diagram of –90°, see also data in catalog supplied by Bosch.

Valve types (overview)

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The selection of a valve for a particular application is made according to thecriteria described below.

The valve size is generally determined by the maximum flow QX. The flow iscalculated from piston area A which is already known (see Section 2.3.1) andrapid traverse v according to the following law of flow:

QX=v A

The nominal volumetric flow Qnom when the valve is completely open (i.e. whenactuating signal is U=+ or –10 V) only serves as a rough guide, as this valuerefers to a pressure loss per control edge of ∆p=35 bar or ∆p=5 bar, as stated intable 2-3. The actual flow under practical pressure conditions is calculated ac-cording to the following formula:

∆pXQX=Qnom ∆pnom

The final valve size is calculated by way of the Bosch program “HYDRO 2”,which evaluates the pressures and flows of various alternative sizes.

Table 2-4 Extract from “HYDRO 2” program

1. Given or previously calculated data (input)

Piston diameter D (mm) 63

Rod diameter d (mm) 28

Counteracting force F (kN) 30

Pump pressure pp (bar) 120

2. Alternative valve size selections (input) Alt 1 Alt 2 Alt 3

Rated flow Qnom

(l/min) 24 50 100

Rated pressure drop ∆p (bar) 35 35 35

3. Alternative results on travel-out (output)

Speed v (m/min) 4,6 9,7 19,3

Pressure in A pA (bar) 104.3 104,3 104,3

Pressure in B pB (bar) 10,1 10,1 10,1

Pressure drop in inlet ∆pPA (bar) 15,7 15,7 15,7

Pressure drop in outlet ∆pBT (bar) 10,1 10,1 10,1

PP

PA

Fv

PT=0

PB

∆PPA ∆PBT

Fig. 2-9 Display of parameters calculated in “HYDRO2”

Valve size

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Values with either a linear or knee-shaped characteristic can be selected.The latter are suitable for obtaining a higher resolution in the low signal range(machining) and sufficient flow in the high signal range (rapid traverse).

The definition of the knee-point position as 40% or 60% means that only 10 %of the opening cross-section (flow) is released at 40% or 60% of the control sig-nal (i.e. at U=4 V or 6 V).

The knee-shaped characteristic of the valve must be linearized in the HLA mod-ule to adapt it to the closed-loop control of the entire drive (cylinder).

40

10

+Q

–Q

–UE +UE

Rapid traverse

Machining

velocity

+Q

–Q

–UE +UE

Valve characteristic

Linearized characteristic

Compensation

10

40

Fig. 2-10 Characteristic of servo solenoid valve

Note

Recommended selection:

Servo solenoid valves are generally recommended for applications where thereis a clear separation between machining operation and rapid traverse.

HRV valves (High Response Valve) are characterized by a better dynamic re-sponse, i.e. by a higher limit frequency as compared to servo solenoid valves.They react with greater sensitivity to setpoint changes especially in the small-signal range. The use of HRVs is recommended in the following cases:

1. When extremely high contour precision is required in high-speed continu-ous-path control machining operations.

2. When very high response sensitivity is required to achieve the best possiblepositioning accuracy.

It must be noted that HRVs do not generally have a “fail-safe” position. The con-nector has 12 pins instead of the 7-pin connector on servo solenoid valves.

Characteristic

Servo solenoid orHRV valves

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Directly actuated, servo solenoid valves have a “fail-safe” position which theyassume when the power supply is disconnected so as to ensure that the cylin-der remains stationary. However, when the power supply is connected and dis-connected or the valve is forced to slide through the crossed position, briefreactions at the cylinder end cannot be precluded.

An absolutely safe stop with loaded cylinder (e.g. vertical mounting position)can only be guaranteed with a “fail-safe” valve in conjunction with additionalshutoff valves.

Pilot-actuated servo solenoid valves and HRVs have no defined “fail-safe” posi-tion. They assume a zero-overlapped mid-position (not a safe stop position)when the supply is disconnected.

A B

P T

A B

P T

Fail-safe disabled (a) Fail-safe enabled

Fig. 2-11 “Fail-safe” position (symbol)

Pilot-actuated servo solenoid valves with asymmetrical throttle cross-sectionsare used to achieve a sufficiently powerful throttling effect when lowering verticaldifferential cylinders with suspended load on the piston rod.

+Q

–Q

–UE +UE

PA

PB

QA

QB

v

A B

P T

G

Fig. 2-12 Asymmetrical characteristics

“Fail-safe” position

Asymmetricalcharacteristics

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A distinction must be made between servo solenoid valves and HRVs.

Servo solenoid valves (directly and pilot-actuated): 7-pin round connector

+24 V=ABCDEF

100k100k10k

2.5 AF

0 V Supply

Reference point for actualvalve spool value

Setpoint 0...10 V

Actual value spool valueProtective earth

Screening

0 V

Sign.

Fig. 2-13 Connector pin assignment on servo solenoid valves

HRV valves (directly and pilot-actuated); 12-pin round connector

+UB

+24 V=

123456

100k100k10k

2.5 AF

0 V Output stage supply

Error message

Enable signal

Setpoint 0...10 V

Actual value spool value

Protective earth

Electronics supply

789

1011

Screening

Enable acknowledgement

24 V

24 V

24 V

0 V

Sign.

0 V

+24 V =/v0.5 A

Fig. 2-14 Connector pin assignment on on HRVs

The following tables list all servo solenoid valves supplied by BOSCH for which technical data are stored in the HLA module.(HLA FW version 01.01)

Connector pin assignments

Preferred range ofservo solenoidvalves

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Table 2-5 Size 6 servo solenoid valves, directly actuated

Bosch order number

Qnom (l/min)at 35 bar(100%)

Characteris-tic kneepoint

(%)

No. ofconnec-tor pins

Graphic symbol Boschcatalog

0 811 404 600 4 linear 7-pin A B AKY 013/2

0 811 404 601 12 linearA

0 811 404 602 24 linearP T

0 811 404 603 40 linearP T

0 811 404 610 4 linear A B

0 811 404 611 12 linear

0 811 404 612 24 linearP T

0 811 404 613 40 linearP T

0 811 404 642 15 60 A B

0 811 404 643 25 60

0 811 404 644 40 40 P T

0 811 404 645 15 60 A B

0 811 404 646 25 60

0 811 404 647 40 40 P T

0 811 404 648 A:40; B:201) 40 A B

P T

0 811 404 649 A:40; B:201) 40 A B

P T


Bosch order number



(%)



0 811 404 800 50 linear 7-pin A B AKY 013/2

0 811 404 801 100 linearP T

0 811 404 802 50 linear A B

0 811 404 803 100 linearP T

0 811 404 822 50 40 A B

0 811 404 823 100 40P T

1) Asymmetrical characteristic

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Bosch order number



(%)



0 811 404 824 50 40 A B AKY 013/2

0 811 404 825 100 40P T

0 811 404 826 A:50; B:251) 40 A B

0 811 404 827 A:100; B:501) 40P T

0 811 404 828 A:50; B:251) 40 A B

0 811 404 829 A:100; B:501) 40P T

Table 2-7 Size 10 servo solenoid valves, pilot-actuated

Bosch order number



(%)



0 811 404 686 40 40 7-pin A Bs u

AKY 013/2

0 811 404 687 70 40s u

s u

0 811 404 688 A:40; B:201) 40 P T

s

X Yu

0 811 404 689 A:70; B:401) 40P TX Y

Table 2-8 Size 16 servo solenoid valves, pilot-actuated

Bosch order number



(%)



0 811 404 263 90 40 7-pin A Bs u

AKY 013/2

0 811 404 264 150 40s u

s u

0 811 404 265 A:90; B:501) 40 P T

s

X Yu

0 811 404 266 A:150; B:901) 40P TX Y


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Table 2-9 Size 6 high-response valves, directly actuated

Bosch order number



(%)



0 811 404 720 40 linear 12-pin A BS

BEY 013/31

0 811 404 721 24 linearB

HRV – Size 6

0 811 404 722 12 linearP T

0 811 404 723 8 linearP T

0 811 404 725 15 60

0 811 404 726 25 60

0 811 404 727 40 40

0 811 404 728 A:40; B:201) 40

Table 2-10 Size 10 high-response valve, pilot-actuated

Bosch order number



(%)



0 811 404 693 40 40 12-pin A B BEY 013/31

0 811 404 694 70 40

0 811 404 695 A:40; B:201) 40P TX Y

0 811 404 696 A:70; B:401) 40P TX Y

Table 2-11 Size 16 high-response valves, pilot-actuated

Bosch order number



(%)



0 811 404 296 90 40 12-pin A B BEY 013/31

0 811 404 297 150 40

0 811 404 298 A:90; B:501) 40P TX Y

0 811 404 299 A:150; B:901) 40P TX Y


2.3.3 Selection of shutoff valves

References: Bosch BEY 010/4

Additional shutoff valves, mounted as an intermediate plate below the servosolenoid valve, ensure that the drive is switched on and off safely and preventbacklash on transition from the “fail-safe” position to mid-position and viceversa.

With external loads (vertical mounting), shutoff valves can prevent any inadver-tent cylinder movement (downwards) when the control loop is not active.

General

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The shutoff valves are automatically enabled and disabled in the correct switch-ing sequence by the HLA module.

Start precondition: The hydraulic pressure must be available beforethe system is switched on.

!Warning

In the event of sudden failure (e.g. open circuit) of the external 24 V supply, anaxial storage capacitor on the HLA module provides energy to supply the servosolenoid valve until such time as the pressure supply for a configured shutoffvalve is disabled.

The machine manufacturer must verify the interaction between valves, makingallowance for all tolerances in the controlled system. The energy content of the storage capacitors is dependent upon

the tolerances of the capacitors,

the voltage level of the external supply and

the charging time of the integrated capacitors (instant of voltage failure).

The available reaction time is mainly defined by

the power required for the current machining step,

the response time of the shutoff valves and

the trip threshold of the servo solenoid valves.

A B

P T

S U

b

T B AP

a

Servo solenoidvalve

Shutoff valve

Fig. 2-15 Example of a shutoff valve application

Example

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A B

P T

S U

b

T B AP

a

Servo solenoidvalve

Shutoff valve(additionalblock)

Fig. 2-16 Example of application of shutoff valve with additional block

The following table lists all shutoff valves supplied by BOSCH that can be usedin conjunction with HLA modules.

Table 2-12 Shutoff valves

Bosch order number

Nominalsize


0 811 024 120 Size 6 P’

a

T’ A’ B’ BEY 010/4

0 811 020 040 Size 10

P

a

T A B

0 811 024 125 Size 6

P

P’

T’ A’ B’

T A B

0 811 024 123 Size 6

P

P’

b

T’ A’ B’

T A B

BEY 010/4

0 811 004 102 Size 6

A

A’

a

P’ T’

P T

B’

B

Preferred range ofshutoff valves

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Table 2-12 Shutoff valves

Bosch order number

Boschcatalog

Graphic symbolNominalsize

0 811 004 103 Size 6

A

A’

b

B’ P’

B P

T’

T

0 811 004 104 Size 6

B

B’

a

A’ P’

A PT

T’

0 811 024 122 Size 6

A

A’

b

T’ P’

T PB

B’

a

0 811 024 121 Size 6

P

P’

B’ T’

B TA

A’

2.3.4 Natural frequency of hydraulic drive

The implementable servo gain is essentially determined by the natural fre-quency of the cylinder and its load ω0 and the limit frequency of the servosolenoid valve ωv.

The cylinder and its load constitute a spring/mass system whose natural fre-quency is calculated according to the following formula:

2

A

m h( )ωo 1 + α

m

h

4 E A

AR

The letters have the following meaning: E=Modulus of elasticity 1,1 109 (N/m2)

A=Piston area (m2)AR=Ring surface(m2)h=Stroke (m)α=Surface ratio AR/Am=Mass (kg)

Oil volumes in the cylinder pipes must also be taken into account.

The minimum natural frequency occurs only at a particular mid-position andincreases as the end positions are approached.

The calculation is made by means of the “HYDRO 2” program.

Servo gain

2 Configuring


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Table 2-13 Extract from “HYDRO2” program

1. Alternative cylinder data (input) Alt 1 Alt 2 Alt 3

Piston diameter D (mm) 50 63 80

Rod diameter d (mm) 22 28 36

Stroke h (mm) 500 500 500

Mass on piston rod m (kg) 150 200 400

Servo solenoid valve, size Size6

Size10

Size10

Limit frequency of servo solenoid valve fv (Hz) 85 45 45

Pipe length (cylinder/valve) (mm) 200 200 200

Internal pipe diameter (mm) 8 12 14

3. Calculated alternative results (outputs)

Natural frequency of cylinder f0 (Hz) 56,6 54,6 55,0

Natural frequency of hydraulic drive (incl. servosolenoid valve)

ft (Hz) 34 24,7 24,8

Stroke at which min. natural frequency occurs hx (mm) 265 266 266

Dm

hhx

d

f0

(oscillating mass)

The natural frequency of the hydraulic drive is automatically calculated by theHLA module and applied in the controller once the corresponding data havebeen parameterized. See also the following machine data in Sections 4.8 and4.9:

MD 5131: CYLINDER_PISTON_DIAMETER...MD 5136: CYLINDER_DEAD_VOLUME_B

MD 5140: VALVE_CYLINDER_CONNECTION...MD 5143: PIPE_INNER_ DIAMETER_A_B

MD 5150: DRIVE-MASS...MD 5152: CYLINDER_FASTENING

MD 5160: PISTON_POS_MIN_NAT_FREQ...MD 5163: DRIVE_NATURAL_FREQUENCY

The feasible dynamics of the servo solenoid valves (e.g. Bosch servo solenoidvalves used) is dependent on the valve modulation and is stated in the Boschcatalog in Hz for the –90° corner frequency fo .

In the case of pilot-actuated valves, the valve dynamic response is not only de-termined by the valve type, but also by the pilot pressure ppilot :

f ppilot0 ~

The Bosch catalog data are referred to a pilot pressure of 100 bar.

Servo-valves can reach corner frequencies of up to 1000 Hz, but are very sen-sitive to contamination.

Feasible dynamics

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2.3.5 Hydraulic power unit

The hydraulic power is supplied by a hydraulic power unit installed separately orintegrated in the machine. The power unit is configured individually to meet therequirements of all hydraulic loads. The following factors are of particular impor-tance:

This is calculated by the HYDRO 2 computation program on the basis of thecylinder data, load forces and pressure drop across the servo solenoid valve.The usual system pressure for machine tool feed drives is within the 40...100bar range.

The maximum flow rate is calculated from the rapid traverse velocity.

If several cylinders are operating simultaneously, the sum of all loads must betaken into account.

Maximum flow is often reached for only brief periods and can be supplied by anaccumulator.

The pump capacity is selected to satisfy the mean flow rate.

The power P output by the E motor to the pump drive is calculated from theproduct of pressure p and flow Q.

P=pQ

Variable displacement pumps with pressure regulators in combination with anaccumulator are generally employed in order to prevent power losses and tomatch the energy supply to the fluctuating delivery requirement during the cycle.

Vane pumps have proven successful in the normal pressure range for theseapplications of 70 to 210 bar.

Classic servo-valves with fluid converters as initial stages are extremely sensi-tive to contamination. However, even the control edges of modern servo sole-noid valves require filtration.

In order to guarantee general operational reliability, but more importantly, to pro-tect the control edges against premature erosion and maintain the quality ofzero overlap, the oil contamination must be limited in compliance withClass 7...9 according to NAS 1638.

This is achieved by means of full flow filters of class β10=75 which must be ar-ranged in the pressure pipe directly before the servo solenoid valve.

The most critical phase is start-up, since contamination which has accumulatedprior to installation often causes failures. For this reason, it is advisable to purgethe system before the servo solenoid valves are fitted.

Since considerable power losses that cannot be compensated for solelythrough oil reservoir dissipation occur when the flow is throttled via the controledges on the valve, additional oil/air or oil/water heat exchangers must be pro-vided in most cases.

Pressure p

Flow Q

Drive power P

Pump type

Filtration

Cooling

2 Configuring


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°CP

Q

M

Variable displacement pump with pressure regulator Pressure-relief valve (protection) Accumulator with fail-safe circuit Filters in pressure line Filters in return line Oil/water heat exchanger Oil reservoir

Fig. 2-17 Overview of typical hydraulic power unit

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2.4 Wiring

2.4.1 Internal power supply

Note

The NC CPU is supplied by the SIMODRIVE power supply via the device bus.No provision has been made for any other type of voltage supply and failure touse the supply provided could damage the unit.

The HLA module is integrated as a single module into the network of 840D andSIMODRIVE modules (power supply or incoming supply module, possibly feedmodules and/or main spindle modules). The power supply is fed in via thedevice bus.

The total power requirement for the entire network must be calculated. Thismust not exceed the power supplied by the power supply module.

To facilitate the calculation, each module has a weighting factor.

This can be found in Chapter 9 of the following reference material:

References: /NC60.1/, Catalog SINUMERIK & SIMODRIVE

The sum of electronic and control points must not be larger than stated in thedata sheet of the power supply module.

2.4.2 External power supply

The purpose of the external power supply is to switch and supply thecomponents

closed-loop proportional valves

shutoff valves

pressure sensors

via the closed-loop control.

In principle, stabilized or unstabilized power supplies and switched-mode orin-phase-controlled supplies can be used.

The following points must, however, be noted:

The required voltage tolerance can only be achieved in practice with stabi-lization and preferably switched for the existing currents. The ripple associ-ated with an unstabilized power supply may cause tripping at the lower mon-itoring threshold.

The stabilization has 24000 µF input capacity per module, which can bestbe charged up with a stabilized power supply (with current limitation).

Comments

Connection andpower losscalculation forNCU

Requirements ofexternal 26.5 Vsupply

2 Configuring

2.4 Wiring

04.00

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!Warning

The DC supply must be reliably separated. See also

References: /PHD/, NCU 561.2-573.2 Manual

The DC supply must be connected to the electronics ground of the controlat one point (e.g. X131 on I/RF module. As a general rule, this connectionis already provided as standard in the S7-300 peripherals. See also

References: /EMV/, SINUMERIK, SIROTEC, SIMODRIVE, EMC Installation Guideline

The input for the 26.5 V supply is protected against polarity reversal.

26.5 V 2% must be fed from the external 26.5 V supply to connector X431to supply the hydraulics components servo solenoid valves, shut-off valves,and pressure sensors. The power requirements is calculated from the powerrequired by external components plus 0.1 A for the internal circuit.

The input voltage tolerance is referred to the input terminals of the closed-loop control, the voltage drops on the supply leads are not negligible.

The external 26.5 V supply is monitored for violation of a lower limit in thecontrol.

!Caution

After the external 26.5 V supply has powered up, terminal X431 may no longerbe inserted or switched since the high charging currents can irreparably dam-age the module or external switch.

If the external 26.5 V supply has to be switched, then an external “precharg-ing circuit” (e.g. relay with timer and resistor) must be used.

The 26.5 V outputs are short-circuit-proof or protected by fuses.

The outputs for the shutoff valves are designed as electronic switches withintegrated zener diodes for disconnecting inductive loads. The zener diodesare located between the 24 V input and the output, with a typical zener volt-age of 58 V.

On supply disconnection, the energy produced by the coil inductance andthe valve spool spring, plus the energy supplied from the 24 V source in thezener diode and ohmic resistance in the solenoid coil is converted to heat.This energy must not exceed 1.7 J during one power OFF process or elsethe zener diode will be destroyed; no electronic protection against this typeof overload is available.

Other requirements of the external 26.5 V supply:

– Voltage range (mean value) 25.97 V to 27.03 V DC

– Ripple 240 mVpp

– No voltage dips, otherwise disconnection

2 Configuring

2.4 Wiring

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The SITOP power product range supplied by SIEMENS is recommended foruse as the external 26.5 V power supply.

References: Catalog, SITOP power from 2 to 40 AOrder No. E800001-V0752-A253

SITOP power for mains connection

The following types from the SITOP power product range are recommendedfor the power supply acc. to the followihg table (24 V DC/10 A; 20 A; 30 A,40 A three-phase):

Table 2-14 SITOP power for mains connection

Input Output Order No.

Voltage Ve rated

Voltage range Voltage Va

Current Ia rated

400 V 3 AC/480 V

360...550 V 24 V DC(24 28 8 V)

10 A 6EP1 434 – 1SH01480 V (24...28.8 V)

tol. 1% 20 A 6EP1 436 – 1SH01

400 V 3 AC 340...460 V 30 A 6EP1 437 – 1SL01

40 A 6EP1 437 – 1SL01

HLA module

SITOP

Mains

M

L+ (26.5 V)AC/DC

X131

NE module

L1L2L3

PE

X431P24EXTINM24EXTIN5

6

Fig. 2-18 Connection of external 26.5 V SITOP power for mains connection

SITOP power for DC link connection

(available soon)

Recommendedpower supply

2 Configuring

2.4 Wiring

04.00

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2.4.3 Earthing system/electromagnetic compatibility (EMC)

The 840D system with HLA module consists of a number of individualcomponents. The individual components are listed below:

I/RF infeed/regenerative feedback module

NCU box

HLA module

MCP machine control panel

Qwerty keyboard

Operator panel components (various monitors with different MMC CPUs)

Terminal block (NCU and L2-DP)

Distribution box and hand-held unit

The individual modules are bolted to a metal cubicle panel. It must be ensuredthat a low-impedance contact between the NCU box and the cubicle panel canbe made in the vicinity of the mounting screws. Insulating varnishes must beavoided where possible.

The electronic ground connections of the modules are interconnected via thedevice and drive buses and taken to terminal X131 on the I/RF module at thesame time.

The internal electronics ground of the HLA module is directly connected to themetal front (module) plate.

Operator panel

ÏÏÏÏÏÏÏÏÏ

EPB/PE EPB/PE

HLA mod-ule

Machine base

Earthing bar

Central earth connection

EPB/PE

EPB

Gatingelectronics

NCU

Machine

control panel

S7-300 peripherals

EPB

tGr

tGr: Shielded signal cable referred to groundEPB: Equipotential bonding conductorPE: Protective earth

– Ground (chassis) –

MMC

EPB/PE

Terminalblock

EPB/PE

Distribu-tion box

Cross-sections (mm2)

10Mains connection S PE minimum

S 1616 S 35S 35

S16S / 2

tGr

Hydraulic drive

Fig. 2-19 Earthing system

Please note the following in relation to electromagnetic compatibility:References: /EMV/, EMC Installation Guidelines

Standards according to Declaration of Conformity (Appendix E)

2 Configuring

2.4 Wiring

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2 Configuring

Notes


Start-Up

3.1 Overview of start-up process

Selection list:Valve data

Controllerdata

Data input

Calculatecontroller data

Calculate drivemodel data Model

data

List selection Cylinder dataMechanicaldata

Data input Data input

Fig. 3-1 Overview of start-up process

Specially designed start-up menu displays are provided by the SINUMERIK 840D control system.

Instructions for calling menu displays can be found in:

References: /IAD/, Installation and Start-Up Guide

The hydraulic linear drive (HLA) is displayed as follows next to the electricdrives (SRM, ARM and SLM) in the “Machine configuration” screen (basicstart-up display):

Fig. 3-2 Machine configuration (basic start-up display)

Machine configuration

3

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Hydraulic linear drives (HLA) are adapted to the machine by means of machinedata.

For this purpose, softkey “Drive MD” is included in the machine data menualong with the other softkeys

General MD

Channel MD

Axis MD

Display MD

Softkey “Drive MD”.

The following list shows the general steps to be taken to start up an HLA mod-ule.

1. Select a valve Select a valve in list

2. Enter cylinder data

3. Mounting/supply data

4. Measuring system data

5. Calculate controller data, save boot file, NCK reset.

6. MD 5475: OUTPUT_VOLTAGE_LIMIT output voltage limitation to low valuesto check the control direction.

7. Approach reference point and adjust position;Position adjustment if piston is in A position at end stop.

8. Adjust pressure sensors (MD 5550, MD 5551, MD 5552, MD 5553, MD 5704, MD 5705, MD 5708). Adjust “manually” via these machine data orautomatically via MD 5650. Enter 1000 Hex in MD 5650. Data are reset to 0after approximately 2 s and the sensors then adjusted. The sensors must beunpressurized during adjustment.

9. Perform offset compensation with MD 5470.Automatic offset compensation is possible via MD 5650 if 2000 Hex is en-tered in MD 5650. Automatic offset compensation takes approximately 30 sand functions only if the P and I components of the velocity controller areactive and all enabling signals are set (see Service Drive).

10. Reduce valve knee-point voltage in MD 5111 by 2...3% if necessary.

11. Area adaptation in MD 5462, set MD 5463 such that the control difference inthe positive and negative traversing directions is almost identical.

12. Friction compensation and force limitationMD 5241=1000 Hex Force limitation activeMD 5241=2000 Hex Friction compensation activeMD 5241=3000 Hex Force limitation and friction compensation active

Machine data

Start-up sequence

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3.1 Overview of start-up process

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3.2 Drive configuration

You must configure the drive bus before you can start up the drives. Do this bypressing softkey “Drive configuration”.

Fig. 3-3 “Drive configuration” menu display

The selected drive type (hydraulic linear drive in this example) is stored in NCmachine data: DRIVE_TYPE.

Table 3-1 Abbreviations of drive types

Drive Motors Contents ofMD 13040 DRIVE_TYPE

SRM (FDD) Synchronous rotating motor (1FT6...) 1

ARM (MSD) Asynchronous rotating motor (1PH...) 2

SLM Synchronous linear motor (1FN...) 3

HLD Hydraulic linear drive 5

ANA Analog drive 4

PER Peripherals 0

You can commence with the drive start-up process once you have set (at least)the following axis-specific machine data

MD 30110: CTRLOUT_MODULE_NR

MD 30130: CTRLOUT_TYPE

MD 30220: ENC_MODULE_NR

MD 30240: ENC_TYPE

and initiated a NCK power ON/Reset (which opens the “Drive machine data”menu display).

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3.2 Drive configuration

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3.3 Drive machine data

You can use softkeys “Drive +” and “Drive –” to scroll through all digital (SRM,ARM, SLM and HLA) drives listed in the drive machine data.

Fig. 3-4 “Drive machine data” menu display

The softkey “Motor/Controller...” is renamed “Valve/Controller...” for the HLA.

Softkey “Valve/Controller...” changes the keys of the vertical softkey menu forthe HLA as follows:

(see Fig. 3-6)

(see Fig. 3-13)

(see Fig. 3-15)

Drive +

Drive –

Directselection...

Valve/Controller...

Boot file/NCK Res...

Search...

Continuesearch

Displayoptions...

Filefunctions

Drive +

Drive –

Directselection

Valveselection...

Changevalve data...

Calculatecontrollerdata...

<<

Filefunctions

Pistonposition... (see Fig. 3-21)

Fig. 3-5 Rearrangement of vertical softkey menu for HLA

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3.3 Drive machine data

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3.4 Valve selection

3.4.1 General

You can select the servo solenoid valve from a list during initial start-up of theSIMODRIVE 611 system. Once you have made your selection, the defaults ofthe valve machine data are overwritten.

If the valve you want to use is not included in the list, you must enter the valvemachine data manually.

This softkey starts the user-prompted start-up process for the HLA module.

You can select a valve from a list stored in the module software, or a non-listedvalve, in the following menu display.

Fig. 3-6 “Valve selection for HLA” menu display

Enter “Unlisted valve” to call a new menu display (see Fig. 3-7) in which thecorresponding machine data can be entered manually.

Choose softkeys “Search...” and “Continue search” to look for any characterstring within the list.

Select softkey “Back” to return to the previously displayed menu. Thissoftkey is disabled in menu display 3-6.

Note

When you select “Abort”, the program branches back to the drive machine datadisplay (see Fig. 3-5), both in this screen and the following menu displays foruser-prompted start-up. The “Abort” softkey also activates a prompt box inwhich you must confirm that you really want to abort start-up for this drive.

No data are ever changed when you select “Abort”. This also applies to thefollowing menu displays.

“Valve selection...”softkey

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3.4 Valve selection

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If you select entry “Unlisted valve”, choose softkey “Continue” to go to menudisplay “Unlisted valve data for HLA” (see Fig. 3-7). If you press softkey “Con-tinue” otherwise, the machine data assigned to the entry are written to a bufferwhose contents are transferred to the drive at the end of the start-up process.You can then go to menu display “Cylinder data” (see Fig. 3-9).

The following data are output in the MMC list display for a stored valve whenone is selected:

Make e.g.: Bosch

Order No. e.g.: 0811404829

Name e.g.: size 10

Rated flow rate e. g.: 100 l/min

Knee-point voltage e.g.: Knee 40%

Rated flow rate A:B e.g.: 2.0

Code e.g.: 52

If you select a valve from the list, the following machine data are preset (i.e. theirdefault setting is overwritten):

MD 5106: VALVE_CODE (valve code no.)

MD 5107: VALVE_NOMINAL_FLOW (rated flow rate of valve)

MD 5108: VALVE_NOMINAL_PRESSURE (rated pressure drop of valve)

MD 5109: VALVE_NOMINAL_VOLTAGE (rated valve voltage)

MD 5110: VALVE_DUAL_GAIN_FLOW (knee-point flow rate of valve)

MD 5111: VALVE_DUAL_GAIN_VOLTAGE (knee-point voltage of valve)

MD 5112: VALVE_FLOW_FACTOR_A_B(rated flow rate ratio between A and B ends of valve)

MD 5113: VALVE_CONFIGURATION (valve configuration)

MD 5114: VALVE_NATURAL_FREQUENCY (natural frequency of valve insmall-signal range)

MD 5115: VALVE_DAMPING (valve damping)

List selection ofvalve

Loaded valve data

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3.4 Valve selection

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When you select an unlisted valve, you must enter the valve machine datamanually. You can also preset the machine data to the settings of a similarvalve.

Fig. 3-7 “Unlisted valve data for HLA” menu display

Press the “Continue” softkey to call menu display “Cylinder data”. These dataare also transferred to the drive at the end of the start-up operation.

By pressing vertical softkey “Preset”, you can go to the corresponding menudisplay in which you can preset machine data by selecting “OK”. You then re-turn to menu display “Unlisted valve data for HLA”.

Fig. 3-8 Menu display “Preset unlisted valve for HLA”

When you press “OK”, the machine data in menu display “Preset unlisted valvefor HLA” are preset. You then return to this menu display.

Unlisted valve data

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3.4 Valve selection

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3.5 Cylinder selection

The following cylinder data must be entered manually:

MD 5131: CYLINDER_PISTON_DIAMETER(piston diameter of cylinder)

MD 5132: CYLINDER_ROD_A_DIAMETER(cylinder piston rod diameter at A end)

MD 5133: CYLINDER_ROD_B_DIAMETER(cylinder piston rod diameter at B end)

MD 5134: PISTON_STROKE(piston stroke)

MD 5135: CYLINDER_DEAD_VOLUME_A(cylinder dead volume at A end)

MD 5136: CYLINDER_DEAD_VOLUME_B(cylinder dead volume at B end)

MD 5160: PISTON_POS_MIN_NAT_FREQ(Min. natural frequency, piston position)

Fig. 3-9 “Cylinder data for HLA” menu display

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3.5 Cylinder selection

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3.6 Mounting/supply data

Fig. 3-10 “Mounting/supply data for HLA” menu display

By selecting softkey “Back”, you can return to the “Cylinder data for HLA” menudisplay. Then press “Continue” to go to the “Measuring system data for HLA”menu display.

The following mounting and supply data must be entered manually.

MD 5100: FLUID_ELASTIC_MODULUS (modulus of elasticity of hydraulicfluid)

MD 5101: WORKING_PRESSURE (system pressure)

MD 5102: PILOT_OPERATION_PRESSURE (pilot pressure, for pilot-actu-ated valves only)

MD 5140: VALVE_CYLINDER_CONNECTION (valve-cylinder connection configuration)

MD 5141: PIPE_LENGTH_A (pipe length at A end)

MD 5142: PIPE_LENGTH_B (pipe length at B end)

MD 5143: PIPE_INNER_DIAMETER_A_B (inner pipe diameter A-B (nominal diameter))

MD 5530: CYLINDER_SAFETY_CONFIG (protection circuit)

MD 5150: DRIVE_MASS (moved mass of drive)

MD 5151: CYLINDER_A_ORIENTATION (mounting position A end of cylinder)

MD 5152: CYLINDER_FASTENING (cylinder mounting)

Supply unit

Connection

Drive data

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3.6 Mounting/supply data

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3.7 Measuring system data

Fig. 3-11 Menu display “Measuring system data HLA, incremental”

To parameterize the encoder, one of the options “Incremental” or “Absolute”(EnDat interface)” must be selected.

The value of the associated machine data is displayed as the scale graduation.You can return to menu display “Mounting/supply data for HLA” by selectingsoftkey “Back”.

You can terminate the start-up operation for this drive by selecting softkey“Ready”.

A dialog message then appears. This must be acknowledged with “Abort” or“OK”.

Fig. 3-12 Dialog message “Start-up ready”

You can return to menu display “Measuring system data for HLA” by selectingsoftkey “Abort”.

When you press “OK”, the machine data are written to the drive. The drivemodel and controller data are then calculated and the boot file saved. The pro-gram then branches to the vertical softkey menu associated with softkey “Valve/controller...” (see Fig. 3-5) in which the data can be checked and altered throughselection of “Change valve data”.

The remaining drives can then be started up.

The entered/calculated data can be activated by an NCK power On/Reset.

Softkey “Ready”

Activation of data

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3.7 Measuring system data

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3.8 Changing data

The following menu display appears when you select softkey “Change valvedata” (see Fig. 3-5):

Fig. 3-13 Menu display “Change data for HLA”

If you press “Abort”, the old machine data settings remain valid and you returnto the initial menu display (see Fig. 3-5).

Softkeys “Valve data...” , “Cylinder data...” and “Mounting data...” each call adisplay that has the same format as the following screenshot except for displayheader and contents (e.g. valve data for HLA):

Fig. 3-14 Menu display “Valve data for HLA”

You can return to menu display “Change data for HLA” (see Fig. 3-13) by press-ing “Abort” or “OK”.

Changing valvedata

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3.8 Changing data

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The data entered for valve and cylinder and the mounting/supply data are usedto preset the following data when you activate “Calculate drive model data”.These settings can be changed manually afterwards. It is advisable to confirmthe calculated model data by carrying out tests on the drive and correct them inaccordance with the test results. MD 5401: DRIVE_MAX_SPEED (maximum useful velocity) MD 5440: POS_DRIVE_SPEED_LIMIT (positive velocity setpoint limit) MD 5441: NEG_DRIVE_SPEED_LIMIT (neg. velocity setpoint limit) MD 5160: PISTON_POS_MIN_NAT_FREQ (min. natural frequency,

piston position) MD 5161: DRIVE_DAMPING (drive damping) MD 5162: DRIVE_NATURAL_FREQUENCY_A (natural frequency of

drive A) MD 5163: DRIVE_NATURAL_FREQUENCY (natural frequency of drive) MD 5164: DRIVE_NATURAL_FREQUENCY_B (natural frequency of

drive B) MD 5231: FORCE_LIMIT_WEIGHT (weight force limitation) MD 5240: FORCECONTROLLED_SYSTEM_GAIN

(controlled system gain force controller) MD 5435: CONTROLLED_SYSTEM_GAIN (controlled system gain) MD 5462: AREA_FACTOR_POS_OUTPUT (fact. area adaptation pos.) MD 5463: AREA_FACTOR_NEG_OUTPUT (fact. area adaptation neg.)The data entered for valve, cylinder, mounting/supply and drive model are usedto preset the following data when you activate “Calculate drive model data”.These settings can be changed manually afterwards. MD 5242: FORCECTRL_GAIN (P-gain of force controller) MD 5243: FORCECTRL_GAIN_RED (reduction of force controller P gain) MD 5244: FORCECTRL_INTEGRATOR_TIME (force controller reset time) MD 5245: FORCECTRL_PT1_TIME (smoothing time const. of force contr.) MD 5246: FORCECTRL_DIFF_TIME (force controller D-action time) MD 5476: OUTPUT_VOLTAGE_INVERSION (manip. variable inversion) MD 5464: POS_DUAL_GAIN_COMP_FLOW

(knee compensation pos. flow) MD 5465: POS_DUAL_GAIN_COMP_VOLTAGE

(knee compensation pos. voltage) MD 5467: NEG_DUAL_GAIN_COMP_FLOW

(knee compensation neg. flow) MD 5468: NEG_DUAL_GAIN_COMP_VOLTAGE

(knee compens. neg. voltage) MD 5406: SPEEDCTRL_GAIN_A (velocity controller A P gain) MD 5407: SPEEDCTRL_GAIN (velocity controller P gain) MD 5408: SPEEDCTRL_GAIN_B (velocity controller B P gain) MD 5409: SPEEDCTRL_INTEGRATOR_TIME[n]

(velocity controller reset time) MD 5413: SPEEDCTRL_ADAPT_ENABLE (sel. of vel. controller adapt.) MD 5414: SPEEDCTRL_REF_MODEL_FREQ[n] (natural frequency of

reference model) MD 5415: SPEEDCTRL_REF_MODEL_DAMPING[n]

(damping of velocity controller reference model) MD 5430: SPEEDCTRL_PT1_TIME (smoothing time constant velocity lead

time) MD 5431: SPEEDCTRL_DIFF_TIME_A[n] (veloc. controller A lead time) MD 5432: SPEEDCTRL_DIFF_TIME[n] (velocity controller lead time) MD 5433: SPEEDCTRL_DIFF_TIME_B[n] (velocity controller B)

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3.8 Changing data

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The modified machine data are transferred to the drive with “OK” (in Fig. 3-13)and, depending on the option settings

calculate drive model data and/or

calculate controller data,

the dialog box “Calculate controller/drive model data” appears with the corre-sponding text (see Fig. 3-15; in this case, for both options).

Fig. 3-15 Menu display “Dialog box for calculate controller/drive data”

By pressing “Abort”, you can return to menu display “Change data for HLA” (seeFig. 3-13).

When you press “OK”, the drive model data and/or controller data are calculatedagain and you finally return to the initial menu display (see Fig. 3-5).

The filters, friction compensation and limitations can be parameterized to suitthe application afterwards.

Softkey “Help” displays a list of those machine data that are changed with soft-key “OK”. In this case as well, the texts are dependent on the set options.

Fig. 3-16 Help screen for changing controller/drive model data

Controller data/Calculate drivemodel data

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3.8 Changing data

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3.9 Fine adjustment and optimization

On completion of start-up, the control loop settings must be checked.

3.9.1 Control direction, travel direction

The control direction can be reversed by the following methods:

Manipulated voltage

Actual value inversion

Scale rotation

Piping A A to A B (inversion)

Any adjustment in the hydraulic piping can be cancelled by inversion of the ma-nipulated voltage.

If the scale is rotated or attached at the wrong point (jacket or rod of cylinder),the control direction can be adjusted by means of actual value inversion.

The manipulated voltage must be limited before the system is first switched onfor a control direction check.

MD 5475: OUTPUT_VOLTAGE_LIMIT 1 V

Note

It is not necessary to determine the control direction if the drive can alreadyoperate in JOG mode. In this case, continue with step 2!

When the enabling signals are set, the axis may move in an uncontrolled man-ner.

Causes:

Incorrect control direction of velocity controller

– Actual value encoder mounting

– Combinatorial connections of servo solenoid valve and cylinder

– Manipulated voltage polarity reversed

Incorrect control direction of position controller

– Actual value encoder mounting

Fig. 3-17 shows the methods which can be used to adjust any uncontrolled tra-versing movements.

Note

When valve end A is connected to cylinder end B (MD 5140=1), inversion ofthe valve manipulated variable (MD 5476) is preset by “Calculate controllerdata”.

General

Limitation ofmanipulatedvoltage

Determinecontrol direction(step 1)

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Change MD 32110: ENC_FEEDBACK_POL (actual value sign)or

invert manipulated voltage MD 5476 and actual value sensing MD 5011.

Step 2

Invert manipulated voltage MD 5476

no

yes, but fails with error message

Do MD 5706 and MD 5707 (vset, vact) have the same sign when the drive starts?

Start

Fig. 3-17 Start-up flow chart, Determine control direction

When the cylinder piston moves in the A B direction (flow Q > 0) , the actualvelocity value Vact must be positive.

This definition must be made in the drive for the associated functionality of

velocity controller adaptation and

force limitation.

zwingend erforderlich.

Input a small positive valve manipulated voltage (function generator)or

traverse the drive in JOG mode to move the cylinder piston from the A to B end!

no

yes

Is cylinder pistonA traversing ! Band is MD 5707positive?

Step 3

Step 2

Invert control signal (change MD 5476 bit 0)and

invert actual value (change MD 5011 bit 0)and

change MD 32110: ENC_FEEDBACK_POL (actual value sign)

(adjust sign of actual velocity value)

Fig. 3-18 Start-up flow chart, definition of drive travel direction

Definition of drivetravel direction(step 2)

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The positive direction of travel of the machine is defined by the user.

With adjustment of travel direction with setpoint MD 32100: AX_MOTION_DIR.

Traverse with JOG key(override approx. 10%)

no

yes

Does cylinder movein the set direction ?

End

Step 3

MD 32100: Change AX_MOTION_DIR (travel direction of machine)

(define travel direction of machine)

Fig. 3-19 Start-up flow chart, definition of travel direction in NC

The setpoint limitation must be set in MD 5475: OUTPUT_VOLTAGE_LIMIT to10 V.

3.9.2 Offset adjustment

Note

Only in combination with pressure sensing function.

Condition: Sensors are pressure-free!

Objective: The pressure display should be 0 at 0 pressure.

Adjustment:

MD 5650: Set DIAGNOSIS_CONTROL_FLAGS bit 12 (cancelled automati-cally after 2 s).

Pressure sensor A:MD 5551: PRESSURE_SENS_A_OFFS is automatically adjusted.

Pressure sensor B:MD 5553: PRESSURE_SENS_B_OFFS is automatically adjusted.

The display for the two pressures (MD 5704, MD 5705) should then showabout 0.0 bar.

Definition of traveldirection in NC(Step 3)

Cancel manipulated voltagelimitation

Offset of pressuresensors

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Note

Only in combination with pressure sensing function.

Enter characteristic data of pressure sensors from data sheet in

MD 5550: PRESSURE_SENS_A_REF (reference value for pressure sensorA)

MD 5552: PRESSURE_SENS_B_REF (reference value for pressure sensorB)

according to data sheet.

Objective: Adjustment of electro-hydraulic zero point

The voltage is adjusted automatically by the following sequence of operations:

Preset velocity controller with I component (e.g. Vp=–10%, TN=30 ms) (seeSection 4.3.2).

In position-controlled mode at zero speed with all enabling signals applied(drive can be traversed with JOG keys).

Set MD 5650 bit 13. (Bit 13 is automatically reset after about 30 s.)

MD 5470: OFFSET_COMPENSATION offset compensation is set automati-cally.

3.9.3 Velocity compensation

Owing to the tolerances of the valves and drive units with

real areas

real valve edge,

it is advisable to readjust the controlled system gain for the purpose of obtaininga symmetrical actual velocity.

∆vmove out = ∆vmove in

The gain is adjusted via machine data

MD 5435: CONTROLLED_SYSTEM_GAIN (stage 1)

and

MD 5462: AREA_FACTOR_POS_OUTPUT/MD 5463: AREA_FACTOR_NEG_OUTPUT (stage 2).

durchgeführt.

Controller parameters

P: P gain of velocity controller (MD 5406/MD 5407/MD 5408)

I: reset time of velocity controller (MD 5409)

D: D-action time of velocity controller (MD 5431/MD 5432/MD 5433)

must be set to 0.

Reference valuefor pressure sensors

Manipulated valvevoltage offset

Objective

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Use function generator to input a velocity setpoint of vset, offset=0.

Cylindertravel-out

Cylindertravel-in

1

2

t

v

Output curve behavior 1 2Controller=0; D, I, P

Objective of adjustment voff = 0von = 0

1st adjustment stage: Even adjustment for both velocity directionswith MD 5435; Make vset and vact congruentat one end.

Cylindertravel-out

Cylindertravel-in

1

2 = 0

t

2nd adjustment stage: Direction-dependent adjustment with MD 5462and/or MD 5463.

Cylindertravel-out

Cylindertravel-in

1 = 0

2 = 0

t

vset

v

v

vset

vset

vact

vact

vact

3rd adjustment stage:

Fig. 3-20 Adjustment of controlled system gain

Note

Vset is not represented by the “servo trace” function if the setpoint is definedby the function generator.

The setting must be checked at different velocities.– Generally speaking, the average value of the calculated controlled sys-

tem gain must be set or– the gain can be adjusted to match the relevant operating range.

Both methods of adjustment are equivalent, i.e. adjustment by the stage 2method via MD 5462 and MD 5463 produces equivalent results when thepreset value (setting) of the controlled system gain (MD 5435) is applied.

Adjustment of controlled systemgain

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3.9.4 Referencing data for HLA

The position of the cylinder piston is required for functions “Force controller” and“Velocity controller adaptation”. For this purpose, the piston position must beadjusted once after referencing.

This is done by the following sequence of operations:

Reference point approach

Select softkey “Piston position” (see Fig. 3-5)

Move cylinder piston to limit stop at A end

Press softkey “Position adjust.” (see Fig. 3-21) to transfer the value set inMD 5740: ACTUAL_POSITION to MD 5040: PISTON_ZERO.

Save boot file

Fig. 3-21 Menu display “Referencing data for HLA”

Select softkey OK to return to the initial menu display for the HLA.

The following machine data are relevant to the adjustment of the piston position:

MD 5040: PISTON_ZERO (piston zero in relation to machine zero))

MD 5740: ACTUAL_POSITION (actual position in relation to machine zero)

MD 5741: ACTUAL_PISTON_POSITION (piston position in relation to pistonzero)

Note

The piston position adjustment must be repeated if the control direction, refer-ence point offset or travel direction (MD 32110, MD 34090 or MD 32100) in theaxis-specific machine data is changed.

Piston neutralposition

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3.9.5 Controller optimization

The most important travel motions are converted via the feedforward controlpath.

The function of the controller parameters is to dampen the oscillation character-istics of the valve/cylinder grouping.

In this respect, three different scenarios relating to the corner frequency (f) mustbe distinguished:

1. fvalve << fcylinder (f)

The valve cannot actively influence any cylinder frequency that is higherthan the valve corner frequency.

Disturbances with frequencies fSt > fvalve cannot be dampened.

Valve:fv=100 Hz; Dv=0.8

Drive:fa=500 Hz; Da=0.1

Amplitude log frequency curve

Phase frequency curve

log f

log f

101 102 103

101

101 102 103

100

10–1

10–2

10–3

10–4

10–5

–90

–180

–270

Pha

se a

ngle

log

valu

e

Fig. 3-22 Frequency response of controlled system (fvalve << fcylinder )

General

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2. fvalve fcylinder (f)




log f

log f

101 102 103

101

101 102 103

100

10–1

10–2

10–3

10–4

10–5

–90

–180

–270

Pha

se a

ngle

log

valu

e


Fig. 3-23 Frequency response of the controlled system (fvalve fcylinder)

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3. fvalve >> fcylinder (f)

The valve can actively influence all natural frequencies of the drive.




log f

log f

101 102 103

101

101 102 103

100

10–1

10–2

10–3

10–4

10–5

–90

–180

–270

Pha

se a

ngle

log

valu

e


Fig. 3-24 Frequency response of controlled system (fvalve >> fcylinder )

The controller components are optimized in the following order:

1. P component (proportional component)

2. D component (derivative component)

3. I component (integral component)

The preferred method of optimization uses unit step functions (step response)with the function generator (FG) through the input of a velocity setpoint vset.

The measuring function with noise signals (FFT, PBRS) may be difficult to inter-pret owing to non-linearities in the controlled system.

The causes for deviations in the characteristic data are as follows:

Theor. Valve: Real valve

Pipework: Control pressure = f(Q)

Additional valves; Shutoff valves; filters; throttles (pressure measuringplates)

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Relevant machine data:

MD 5406: SPEEDCTRL_GAIN_A (P gain of velocity controller A)MD 5407: SPEEDCTRL_GAIN (P gain of velocity controller)MD 5408: SPEEDCTRL_GAIN_B (P gain of velocity controller B)

The theoretical characteristic data of the valve and cylinder are used to calcu-late a suggested P gain value. The positive feedback area (MD 5406...MD 5408<0) is included in the calculation to damp the drive system.

The adjustment to real conditions on the machine (special damping require-ments) should be made according to the following criteria:

1. P component must be as positive as possible.

Optimization direction

0< 0 > 0

MD 5406

MD 5407

MD 5408

2. The acceptable overshoot behavior represents the upper limit for the setting.

Note

P<0 (positive feedback) may be necessary to achieve the required dampingbehavior. However, this setting will degrade the control quality. Friction in partic-ular causes prolonged settling times.

Threshold values (typical):

f P>0

f P<0, or around zero

f P>0

(f...f see Section 3.9.5 paras. 1...3)

Note

The P gain is specified as a percentage of MD 5435: CONTROLLED_SYS-TEM_GAIN. P=–100% compensates the feedforward control.

Relevant machine data:

MD 5431: SPEEDCTRL_DIFF_TIME_A (Lead time TV of velocity controller A)MD 5432: SPEEDCTRL_DIFF_TIME (Lead time TV of velocity controller)MD 5433: SPEEDCTRL_DIFF_TIME_B (Lead time TV of velocity controller B)

MD 5430: SPEEDCTRL_PT1_TIME (velocity controller smoothing timeconstant)

The positive phase displacement of the derivative term can be utilized to ac-tively dampen the controlled system for f type.

The derivative-action time constant/corner frequency must be parameterized tovalues higher than the minimum natural frequency of valve and drive.

Optimization ofcontroller P component

Optimization ofcontroller D component

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Test run:

As long as the damping effect improves, the the D-action time value can beraised further:

Leave D-action time at its old value if the damping effect does not improve.

(see Fig. 3-22 – f)

The smoothing time constant is set to values 1 ms as a function of the con-trolled system for “calculate controller”.

Owing to the fact that a derivative action amplifies the actual value noise, it isnecessary in this case to find a compromise between

the derivative action (and thus vibration damping)

(set MD 5430: SPEEDCTRL_PT1_TIME as low as possible, i.e. high cornerfrequency of D-action component or wide D-action frequency range)

and

the noise of the manipulated variable.

Like the P component setting, the optimization criterion here is the maximumacceptable overshoot of the closed velocity control loop.

The main area of application is the valve/cylinder combination f (see Fig. 3-24)with values TV>>0.

For applications f + f (see figs. 3-22, 3-23) improvements of the dampingcharacteristics are only to be expected at specific points when TV0, in mostcases TV=0 is the best choice.

Note

A second iteration loop (optimize P and D components) with further improve-ments can be connected in series downstream.

Integrator/reset time (TN)

Objective: Elimination of errors in feedforward control channel.

Implementation: TN>5 ms, taking the overshoot behaviorof the valve frequency response into account.

Note

The I component is deactivated if TN=0 (MD 5409) or if the P component iszero (MD 5406=0, MD 5407=0, MD 5408=0).

Optimization ofcontroller I component

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3.9.6 Controller adaptation

Since the natural frequency of the cylinder changes as a function of position, itmay be useful to adapt the position of the velocity controller. The maximum val-ues coincide with the limits, and the minimum approximately with the center (MD5160), of the traversing range.

Preconditions:

NC end has been referenced.

Cylinder piston in neutral position has been adjusted according to Section3.9.4.

Control parameters have been processed according to the relevant operat-ing range.

Procedure:

Optimize the velocity controller (P and D components) with the associatedmachine data at the limits and at position set in MD 5160.

Example: (cf. Fig. 4-10) operating range = total piston stroke

Interpolation point 1 Optimization to A end of cylinder MD 5406: SPEEDCTRL_GAIN_A (P gain) MD 5431: SPEEDCTRL_DIFF_TIME_A (D gain)

Interpolation point 2 Optimization to piston position as set inMD 5160: PISTON_POS_MIN_NAT_FREQ MD 5407: SPEEDCTRL_GAIN (P gain) MD 5432: SPEEDCTRL_DIFF_TIME (D gain)

Interpolation point 3 Optimization to B end of cylinder MD 5408: SPEEDCTRL_GAIN_B (P gain) MD 5433: SPEEDCTRL_DIFF_TIME_B (D gain)

Note

If one end of a cylinder cannot be approached, then the adaptation processcan be limited to two interpolation points.

Velocity controller adaptation activeMD 5413: SPEEDCTRL_ADAPT_ENABLE=1

Note

SPEEDCTRL_ADAPT_ENABLE=1 (MD 5413) is switched through onlywhen the axis has been referenced and adjusted.

With f (see Section 3.9.5), adaptation is deactivated during “Calculatecontroller data”.

General

Implementation

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3.9.7 Hydraulic/electrical interpolation

Contour accuracy between hydraulic and electrical drives is achieved when thedrive dynamic response is set identically on the involved axes.

In addition to identical servo gain settings, it must be ensured that the step re-sponse of the closed speed controller is “identical”.

A velocity setpoint filter of the faster axis (e.g. electrical) must be set to the dif-ference between the time constants of the closed velocity control loop (Tv, eqv).

Tfilter , el =Tveqv, hyd – Tveqv, el

t

vvact, el

vact, hyd

Teqv, el Teqv, hyd

vw

0.5

Fig. 3-25 Hydraulic/electrical interpolation

When Dynamic Stiffness Control (DSC) is active, the DSC function must be acti-vated on all interpolating axes.

Objective

Implementation

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3.10 File functions

The drive type is recorded in the MD files when drive machine data are saved.Thus, the comment is inserted only if the entry “MdFileDriveType=TRUE” hasbeen set in the [Compatibility] section of INI file “ib.ini”. This setting is the de-fault.

It is only possible to load MD files to the drive which are suitable for the relevantdrive type. If you attempt, for example, to load an MD file for SLM to an HLAmodule, the following message will be displayed:

Fig. 3-26 Menu display “Dialog box for loading machine data”

Fig. 3-27 Menu display “File functions”

Saving data

Loading data

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3.10 File functions

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3.11 Start-up functions

The following start-up functions are implemented for axes with HLA:

Measuring functions

– Measurement of valve control loop

– Measurement of velocity control loop

– Measurement of position control loop

function generator,

Circularity test

Servo trace

DAC configuration

Fig. 3-28 Menu display “Start-up functions”

The softkey “Self-opt. AM/MSD” in the “Start-up functions” menu is also disabledfor axes with HLA since this is a special function for AM/MSD.

Furthermore, softkey “AUT. Controller setting” in the “Startup functions” menu isdisabled for axes with HLA since the algorithms it uses are designed for auto-matic controller setting for electrical digital drives.

Disabled softkeys

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3.11.1 Measurement function

The measurement functions allow assessment of the most important variablesof the speed and position control loop in the time and frequency range withoutthe use of external measuring devices on the screen.

An Overview of the measurement functions provided for HLA is given below,with only the purely hydraulic-specific functionality for HLA described in detail.

The following measuring functions can be performed in conjunction with theHLA:

Valve control loop measurement

– Valve frequency response

Velocity control loop measurement

– Reference frequency response

– Setpoint step change

– Interference frequency response

– Disturbance step change

– Velocity path

– Velocity path + controller

Position control loop measurement

– Reference frequency response

– Setpoint step change

– Setpoint ramp

Table 3-2 Measurement types and quantities for valve control loop measurement

Measurement Trigger Measured quantities

Valve frequencyresponse

Valve spool setpoint in velocity con-troller cycle, valve control loop closed,velocity control loop open

Actual valve spool value/valve spool setpoint

Table 3-3 Parameterization of valve control loop measurement

Parameter Physic. Unit

Amplitude typ 1 V V

Bandwidth typ 1000 Hz Hz

Averaging operations typ 10 –

Settling time typ 100 ms

Offset typ 0 V

Note

It must be ensured that the drive is adequately lubricated before PBRS/FFT isapplied (high-frequency movement at one position).

Valve control loopmeasurement

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20.000

–60.000

+180

–180

Ampl.[dB]

Phase[degrees]

1.000 1.000e+03log [Hz]

1.000 1.000e+03log [Hz[]

Fig. 3-29 Example of valve frequency response on HRV size 06, 15 l/min, knee-point60%. Note: For setting of valve data, see Section 4.7.

Table 3-4 Measurement types and quantities for measurement of velocity controlloop

Measure-ment

Trigger Measured quantities

Referencefrequency re-sponse

Velocity setpoint in velocity controllercycle, valve control loop closed, velocitycontrol loop closed

Actual velocity value/velocity setpoint

Setpoint stepchange


Quantity 1:

Velocity setpoint

Valve spool setpoint

Quantity 2:Actual velocity value

Interferencefrequency re-sponse

Valve spool setpoint in velocity controllercycle, valve control loop closed, velocitycontrol loop closed

Actual velocity value/valve spool setpoint

Disturbancestep change

Valve spool setpoint in velocity controllercycle, valve control loop closed, velocitycontrol loop closed

Quantity 1:Valve spool setpointQuantity 2:Actual velocity value

Velocity con-troller path

Valve spool setpoint in velcoity controllercycle, valve control loop closed, velocitycontrol loop closed

Actual velocity value/actual valve spool value

Velocity con-troller path +controller


Actual velocity value/control deviation

MeasurementVelocity controlloop

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Table 3-5 Parameter settings for measurement of velocity control loop

Parameter Physical Unit

Reference frequency response

Amplitude (linear axis) mm/min | inch/min

Bandwidth Hz

Averaging operations –

Settling time ms

Offset (linear axis) mm/min | inch/min

Setpoint step change


Measuring time ms

Settling time ms


Disturbance step change

Amplitude V

Measuring time ms

Settling time ms


Velocity controller path

Amplitude V

Bandwidth Hz


Settling time ms


Velocity controller path + controller


Bandwidth Hz


Settling time ms


The following functional response in the diagrams were recorded with the equip-ment combination below:

Valve: HRV size 06, 15 l/min, knee-point 60 %

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20.000

–60.000

180.000

–180.000

Ampl.[dB]

Phase

[degrees]

0.100 200.000log [Hz]

0.100 200.000log [Hz]

Fig. 3-30 Oscillogram showing reference frequency response of velocity control loop

Amplitude: 20 mm/min

Offset: 100 mm/min

t [ms]0.000 50.000

Fig. 3-31 Timing of setpoint step change in velocity control loop

Step change: 0 → 100 mm/min without closed-loop force control, real frictionconditions

Trace 1: Velocity setpoint

Trace 2: Actual velocity value

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0.100 100.000t [ms]

Fig. 3-32 Timing of disturbance step change, integral branch of velocity controller deacti-vated

Trace 1: Valve spool setpoint

Trace 2: Actual velocity value

90.000

10.000

180.000

–180.000

Ampl.[dB]

Phase[degrees]

1.000 1000.000log [Hz]

1.000 1000.000log [Hz]

Fig. 3-33 Oscillogram showing velocity controlled system vact/Qact

Note: Phase crossover -90 degrees essentially characterizes the cylinder natural frequency

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20.000

–60.000

180.000

–180.000

Ampl.[dB]

Phase[degrees]

1.000 2000.000log [Hz]

1.000 2000.000log [Hz]Phase margin at 0 dB

Amplitude margin at 180 degrees

0

Fig. 3-34 Oscillogram for velocity controller path + controller

Note: Measurement of open velocity controlled system,indicative of the stability of the control loop.

Target values for stability of control loop:

At least 3 dB amplitude margin at 180 degrees

At least 60 degrees phase margin at 0 dB

Table 3-6 Measurement types and quantities for measurement of position controlloop

Measurement Trigger Measured quantities

Reference fre-quency response

Position setpoint in position control-ler cycle, position control loopclosed, velocity control loop closed

Actual position/position set-point

Setpoint stepchange

Position setpoint in position control-ler cycle, position control loopclosed, velocity control loop closed

Quantity 1:Position setpointQuantity 2: Actual position

Setpoint ramp Control deviation

Following error

Actual velocity

Measurement ofposition controlloop

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Table 3-7 Parameter settings for measurement of position control loop

Parameter Physic. Unit

Reference frequency response

Amplitude (linear axis) mm | inch

Bandwidth Hz


Settling time ms


Setpoint step change


Measuring time ms

Settling time ms


Setpoint ramp


Measuring time ms

Ramp duration ms

Settling time ms


20.000

-60.000

180.000

–180.000

Ampl.[dB]

Phase[degrees]

0.100 125.000log [Hz]

0.100 125.000log [Hz]

Fig. 3-35 Example of measurement of position control loop

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3.11.2 Function generator

The function generator for HLA is based on the existing functionality providedfor other drive types integrated to date. The functionality for HLA, which is notespecially designed for hydraulic drives, is based on the SLM range of func-tions.The function generator excites the drive with a periodic signal. The signal typeis a parameterizable quantity. External measuring instruments such as oscillo-graphs can register the system reactions via DAC output jacks.The following signals (operating modes) and signal types are available on theHLA:

Signals (operating modes)– Valve spool setpoint– Velocity setpoint– Position setpoint

Signal type– Square-wave– Noise signal (only for signal output via DAC and external evaluation

equipment for frequency response analyses)

Fig. 3-36 Menu display “Function generator selection signal”

Fig. 3-37 Menu display “Function generator selection signal type”

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For an explanation of how to use the function generator, please refer to

References: /BF/, DD. “Speed Control Loop”/TIM/, SIMODRIVE 611 “Manual for MK 172A”

An Overview of the function generator functions provided for HLA is given be-low, with only the purely hydraulic-specific functionality for HLA described indetail.

Table 3-8 Signal (operating mode) for valve spool setpoint

Trigger Signal type

Valve spool setpoint in velocity controller cycle, valvecontrol loop closed, velocity control loop open

Square-wave

Table 3-9 Parameterization of signal (operating mode) for valve spool setpoint


Signal type: Square-wave

Amplitude V

Period ms

Pulse width ms

Offset V

Limitation V

t [ms]

1.98902.0510

200.0000

–2.0260–2.0610

VV

Tr. 1: Valve stroke setpointTr. 2: Actual valve stroke

0.0000

Fig. 3-38 Servo trace of actual valve value with square-wave signal type to valve set-point

Valve spool setpoint (manipu-lated voltage)

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Table 3-10 Signal (operating mode) for velocity setpoint

Trigger Signal type

Velocity setpoint in velocity controller cycle, valve controlloop closed, velocity control loop closed

Square-wave

Table 3-11 Parameterization of signal (operating mode) for velocity setpoint




Period ms

Pulse width ms


Limitation (linear axis) mm/min | inch/min

Note

The following diagram was created using a servo trace.

t [ms]0.000 2.000e+03

Fig. 3-39 Servo trace of actual velocity with square-wave signal type to velocity setpoint

Amplitude: 100 mm/min

Velocity setpoint

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Table 3-12 Signal (operating mode) for position setpoint

Trigger Signal type

Position setpoint in position controller cycle, position con-trol loop closed, velocity control loop closed

Square-wave

Table 3-13 Parameterization of signal (operating mode) for position setpoint




Period ms

Pulse width ms


Limitation (linear axis) mm | inch

Note

The following diagram was created using a servo trace.

t [ms]0.000 2.000e+03

Fig. 3-40 Servo trace of actual position with square-wave signal type to position setpoint

Amplitude: 100 mm

Position setpoint

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3.11.3 Circularity test

The circularity test is used among other things as a way of checking the result-ing contour precision. The actual positions of a circular movement are mea-sured and the deviations from the programmed radius (especially at quadranttransition points) displayed graphically. For detailed information, see:

References: /FB/ Part 2, K3, Sect. 2.7 “Circularity test”

Example: The following example refers to a drive with an HRV.

X1 axis: Horizontal movement by electrical driveY1 axis: Vertical movement by hydraulic drive

Scl/Div = 1.000e–03 Radius = 19.999

Tr. 1: X1 axis: Circularity test (electrical axis)Tr. 2: Y1 axis: Circularity test (hydraulic axis)

Fig. 3-41 Example of circularity test on HRV size 06, 15 l/min, knee-point 60%; V=400 mm/min (traversing velocity)

3.11.4 Servo trace

The servo trace function is used for graphic representation of signals and oper-ating conditions.

A hydraulic-specific signal list (servo and drive signals) is available as a supportfunction for axes with HLA module.

The following hydraulic-specific drive signals are supported by the servo trace:

Active power (with pressure sensing)

Actual force (with pressure sensing)

Actual velocity value

Valve stroke setpoint

Actual valve stroke

Actual pressure cylinder A end

Actual pressure cylinder B end

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3.11.5 DAC parameterization

For DAC measuring sockets see Section 5.1.5.

Fig. 3-42 Menu display “DAC parameterization”

Table 3-14 DAC selection list

Designation Unit

Pressure p(A) (with pressure sensing) bar

Pressure p(B) (with pressure sensing) bar

Actual value spool value V

Valve spool setpoint V

Actual velocity value mm/min

velocity Setpoint (at filter input) mm/min

velocity Setpoint (limited at filter output) mm/min

velocity Reference model setpoint mm/min

Actual force (with pressure sensing) N

Active power (with pressure sensing) kW

Control deviation of velocity controller mm/min

Velocity controller P component V

Velocity controller I component V

Velocity controller D component V

Feedforward control component velocity controller V

Friction feedforward control component velocity controller V

Velocity controller output before filter V

Velocity controller output after filter V

Actual position mm

Force setpoint N

Force controller control deviation N

DAC selection list

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Table 3-14 DAC selection list

Designation Unit

Force controller P component V

Force controller I component V

Force controller D component V

Feedforward control component force controller V

Force controller output V

Zero marker signal –

BERO signal –

Physical address (drive) –

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3.12 User views

The horizontal softkey HLA is used under menu items “User Views/Edit View/In-sert Date”.

Fig. 3-43 Menu display “Edit view”

3.13 Display options

The purpose of display options is to allow you to reduce the number of dis-played machine data selectively.

The grouping of machine data for display purposes is implemented in a similarway to the method used on Electrical drives.

Fig. 3-44 Menu display “Display options”

Machine datagroups

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3.12 User views

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3.14 Configuring an OEM valve list

OEM users can add their own valves to the valve list by copying file ibhlvlvo.iniinto directory “\oem”. This list is added as a separate item under the heading“OEM valves” at the end of the system list (Siemens list).

The syntax of the valve list is identical to that of a Windows INI file. The list canbe drawn up under “Start-up”, “MMC”, “Editor”.Mark C:\OEM, “new”, enter filenameibhlvlvo.ini , “Ok”.

This file must be formatted as follows:

[DATA]Column1 = Column2, Column3, ... , Column15,...

[DATA]

ÁÁÁÁÁÁÁÁÁ

;5106ÁÁÁÁÁÁÁÁÁ

,ÁÁÁÁÁÁ

,ÁÁÁÁÁÁÁÁÁ

,ÁÁÁÁÁÁÁÁÁ

5107,ÁÁÁÁÁÁÁÁÁ

5108,

ÁÁÁÁÁÁÁÁÁ

5109,

ÁÁÁÁÁÁ

5110,

ÁÁÁÁÁÁÁÁÁ

5111,

ÁÁÁÁÁÁÁÁÁ

5112,

ÁÁÁÁÁÁÁÁÁ


5114,

ÁÁÁÁÁÁ

5115,

ÁÁÁÁÁÁÁÁÁ

,ÁÁÁÁÁÁÁÁÁÁÁÁ

,

ÁÁÁÁÁÁ

1001=ÁÁÁÁÁÁ

OEM,ÁÁÁÁ

01,ÁÁÁÁÁÁ

Size16,ÁÁÁÁÁÁ

90.1,ÁÁÁÁÁÁ

5,ÁÁÁÁÁÁ

10,ÁÁÁÁ

10,ÁÁÁÁÁÁ

39.8,ÁÁÁÁÁÁ

1)ÁÁÁÁÁÁ

0001B,ÁÁÁÁÁÁ

35,ÁÁÁÁ

1.0,ÁÁÁÁÁÁ

90,ÁÁÁÁÁÁÁÁ

$T740,

ÁÁÁÁÁÁÁÁÁ

1050=ÁÁÁÁÁÁÁÁÁ

OEM,ÁÁÁÁÁÁ


Size10,

ÁÁÁÁÁÁÁÁÁ

40.2,ÁÁÁÁÁÁÁÁÁ


10,ÁÁÁÁÁÁ



1)ÁÁÁÁÁÁÁÁÁ

0001B,ÁÁÁÁÁÁÁÁÁ

35,ÁÁÁÁÁÁ


40,ÁÁÁÁÁÁÁÁÁÁÁÁ

$T740,

ÁÁÁÁÁÁ

1051=ÁÁÁÁÁÁ

OEM,ÁÁÁÁ

03,ÁÁÁÁÁÁ

HRV1,ÁÁÁÁÁÁ

8.1,ÁÁÁÁÁÁ

35,ÁÁÁÁÁÁ

10,ÁÁÁÁ

10,ÁÁÁÁÁÁ

10,ÁÁÁÁÁÁ

1)ÁÁÁÁÁÁ

0000B,ÁÁÁÁÁÁ

200,ÁÁÁÁ

0.8,ÁÁÁÁÁÁ

8,ÁÁÁÁÁÁÁÁ

$T8,

ÁÁÁÁÁÁ

1030=ÁÁÁÁÁÁ

OEM,ÁÁÁÁ

04,ÁÁÁÁÁÁ

Size10,ÁÁÁÁÁÁ

100.1,ÁÁÁÁÁÁ

35,ÁÁÁÁÁÁ

10,ÁÁÁÁ

10,ÁÁÁÁÁÁ

38.5,ÁÁÁÁÁÁ

2,ÁÁÁÁÁÁ

0010B,ÁÁÁÁÁÁ

70,ÁÁÁÁ

0.8,ÁÁÁÁÁÁ

100,ÁÁÁÁÁÁÁÁ

$T740,

$L= “End of list”

$L= “– – – – – – – – –”

Note

Columns 1 and 2 are separated by an “=” symbol, all other columns by acomma. Column 15 is ended by a comma.

An MMC Reset must be performed to make changes effective.

General

Format

Example of anOEM valve list

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3.14 Configuring an OEM-valve list

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Table 3-15 Meaning of individual columnsÁÁÁÁÁÁÁÁÁ

Col-umn inOEM

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

DescriptionÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Column inMMC dis-

play

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Reference to MDÁÁÁÁÁÁÁÁÁÁÁÁ

Unit

ÁÁÁÁÁÁÁÁÁ

OEMvalvelist

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

playName No. ÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁ1ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Valve code no. ÁÁÁÁÁÁÁÁÁÁ

7 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

VALVE_CODE ÁÁÁÁÁÁÁÁ

5106 ÁÁÁÁÁÁÁÁ2 Manufacturer’s name 1

ÁÁÁÁÁÁ

3ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Order No. ÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁ



Designation ÁÁÁÁÁÁÁÁÁÁ


ÁÁÁÁÁÁÁÁ



Rated valve flow ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

VALVE_NOMINAL_FLOW ÁÁÁÁÁÁÁÁ

5107 ÁÁÁÁÁÁÁÁ

[l/min]

ÁÁÁÁÁÁ


Rated pressure drop ofvalve

ÁÁÁÁÁÁÁÁÁÁ


VALVE_NOMINAL_PRESSSURE ÁÁÁÁÁÁÁÁ


[bar]

ÁÁÁÁÁÁ


Rated voltage of valveÁÁÁÁÁÁÁÁÁÁ


VALVE_NOMINAL_VOLTAGEÁÁÁÁÁÁÁÁ

5109ÁÁÁÁÁÁÁÁ

[V]ÁÁÁÁÁÁ


Valve knee-point voltage ÁÁÁÁÁÁÁÁÁÁ


VALVE_DUAL_GAIN_FLOW ÁÁÁÁÁÁÁÁ


[%]ÁÁÁÁÁÁ


Knee-point voltage of valveÁÁÁÁÁÁÁÁÁÁ


VALVE_DUAL_GAIN_VOLTAGE ÁÁÁÁÁÁÁÁ


[%]

ÁÁÁÁÁÁÁÁÁ

10ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Rated flow rate ratio be-tween A and B ends of valve

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

6 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

VALVE_FLOW_FACTOR_A_B ÁÁÁÁÁÁÁÁÁÁÁÁ

5112 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁ


Valve configuration ÁÁÁÁÁÁÁÁÁÁ


VALVE_CONFIGURATION ÁÁÁÁÁÁÁÁ

5113 ÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁ


Natural frequency of valveÁÁÁÁÁÁÁÁÁÁ


VALVE_NATURAL_FREQUENCY ÁÁÁÁÁÁÁÁ


[Hz]

ÁÁÁ13ÁÁÁÁÁÁÁÁValve damping ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁVALVE_DAMPING ÁÁÁÁ5115 ÁÁÁÁ14 Rated valve flow for display 4 [l/min]

15 Valve knee-point voltage fordisplay

5 [%]

The valve code is entered in the first column and must be a number. Numbers 1to 1000 are reserved for Siemens. Individual values are separated by commas.Columns 1 and 2 are separated by an equals signal (=). Comments are pre-ceded by a semicolon.

Different numeric formats may be used.

The following applies to the display (selection list) on the MMC: The character strings used are identical to those stored in the INI file.

The following applies to writing machine data:

– Unless otherwise specified, the decimal format is always used. If thenumber is followed by a capital B, it is interpreted as a binary number. Ifa capital H is inserted after the number, it is interpreted as a hexadecimalvalue.

– Floating-point numbers must be specified in US format (decimalpoint=“.”) and WITHOUT the separator symbol for 1000s (“,”).

– The individual fields in this section can be left empty, i.e. they contain 2commas one after the other or two blanks between the 2 commas.Empty fields are not written to the drive, i.e. the default setting of the ma-chine data is transferred unchanged. The number of blanks is optional.

3 Start-Up


02.99



Any language-dependent texts can be inserted in the OEM valve list. These allstart with $T.

Syntax: $T<X> (no dash dot)In this case, <X> refers to a text in the language-dependenttext files (see also language-dependent OEM texts)

Subheadings can also be inserted in the OEM valve list by adding the instruc-tion “$L=<beliebiger Text>;” at the beginning of a line. $T<X> can be used toinsert other language-dependent texts within this optional text instruction.

The following language-dependent texts are predefined by the system and canbe used in OEM valve lists.

$T1=Order No.;$T2=Name;$T3=Rated flow;$T4=Knee-point voltage;$T5=Rated flow A:B;$T6=Code;$T7=“ Knee”;$T8=“ Linear”;$T9=Company;$T10=Unlisted valve;$T11=l/min;

Language-dependent OEM display texts are stored in directory \oem\languagein files \ibdrv_<SPRACHE>.ini

< SPRACHE > stands for the appropriate language code. This file would benamed ibdrv_gr.ini for German. The codes for all languages installed in a sys-tem are listed in file \mmc2\mmc.ini, section [LANGUAGE], entry LanguageL-ist. Language-dependent OEM text files must be formatted as follows:

[TEXT]$T<X>=<beliebiger Text>; :<X> is any number 1000 and 32767, that must only occur once.

The number range from 1 to 999 is reserved for the system.

Language-dependent texts

Language-dependent systemtexts

Language-dependent OEMtexts

3 Start-Up



Firmware Drive Functions

4.1 Block diagram of closed-loop control

The following block diagram illustrates how the HLA module is embedded be-tween the NC and the hydraulic drive. The control functions of the module areshown in greatly simplified form. They are shown in more detail in the followingdiagram.

DA

Control system Drive

A B

Velocity feedforwardcontrol v’vor

HLA module

Flow feedforward control

Velocity controller

Actual velocity vactActualpositionxact

Position set-point xset

Positioncontroller

Velocity setpointvset

Character-istics com-pensation

Valve setpoint voltageUset

CylindersActual position

Servo solenoid valve

P T

Pressure supply

Valve amplifier

PU

PU

pApB

Fig. 4-1 General block diagram of NC – HLA module – drive system

Dynamic response is dependent upon:

Natural frequency of the servo solenoid valve (see Section 2.3.2)

Natural frequency of the drive (see Section 2.3.4)

The greater the natural frequency, the better the achievable dynamic response.

For the purpose of oscillation damping, the natural frequency of the servo sole-noid valve must be greater than that of the drive.

Overview of system integration

Achievabledynamic response

4

02.99



Fig. 4-2 shows the functionality for velocity and closed-loop force control pluscharacteristics that is implemented in the HLA module.

Set

poin

t v

Vel

ocity

Set

poin

tlim

itatio

n

Vel

ocity

set

P c

ompo

nent

MD

542

1/M

D 5

422

D c

ompo

nent

Lim

itato

n

Are

a ad

apt-

Ada

ptat

ion

Ada

ptat

ion

Fric

tion

inje

ctio

n

Flo

w fe

edfo

rwar

d co

ntro

l

+S

etpo

int f

ilter

Ref

eren

ce

MD

546

0/M

D 5

461

MD

543

5

MD

544

0/M

D 5

441

MD

550

0–M

D 5

502/

MD

550

6/M

D 5

507/

MD

551

4–M

D 5

516/

MD

552

0/M

D 5

004

MD

540

6–M

D 5

408

MD

541

4/I c

ompo

nent

MD

543

0–M

D 5

433

Con

trol

out

put f

ilter

MD

520

0–M

D 5

205/

MD

521

0–M

D 5

215

MD

546

2

Kne

e-po

int

com

pens

atio

nM

anip

ulat

ed v

olta

gelim

itatio

n

to DA

C

Offs

et

Sel

ectio

nlo

gic

atio

n

MD

546

3M

D 5

464–

MD

546

8M

D 5

480–

MD

548

8M

D 5

475

Act

ual v

eloc

ity v

Act

ual p

ositi

on x

mod

el

MD

541

5

act

act

P c

ompo

nent

Ada

ptat

ion

Ada

ptat

ion

I com

pone

nt

Atte

nuat

ion

(val

ve d

ynam

ic r

espo

nse)

F

D c

ompo

nent

Ada

ptat

ion

(see

Sec

tion

4.4,

Fig

. 4-1

1)on

ly if

pre

ssur

e se

nsor

is c

onne

cted

MD

524

5/M

D 5

246

MD

524

4

MD

524

3M

D 5

242

Fee

dfor

war

d co

ntro

l fac

tor

MD

524

7

set

F act

For

ce c

ontr

olle

rM

D 5

230–

MD

523

5M

D 5

241

(con

figur

atio

n)

Con

trol

out

put f

ilter

MD

528

0/52

81M

D 5

284/

5285

MD

528

8-M

D 5

290

Fee

dfor

war

d co

ntro

l filt

er

MD

526

0/52

61M

D 5

264/

5265

/MD

526

8-M

D 5

270

cont

rol

Are

a ad

apt-

atio

nVel

ocity

con

trol

ler

Fig. 4-2 Controllers andcharacteristic functions of HLA module

Block diagram ofcontrol functions

4 Firmware Drive Functions

4.1 Block diagram of closed-loop control

04.00

02.99


4.2 Functions

4.2.1 Overview of functions

The document has been organized under the following main topics according tothe scheme shown in Fig. 4-2:

Velocity feedforward control (Section 4.3.1)

– Controlled system gain

– Velocity setpoint filter

– Setpoint limitations

Velocity controller (Section 4.3.2)

– P/D/I components

– Adaptation

– Integrator feedback

– Reference model

– Control output filter in velocity controller

Closed-loop force control (Section 4.4)

– P/D/I components

– Force limitations

– Controlled system gain

Manipulated voltage output (Section 4.5)

– Characteristic compensation

– Control output filter

– Manipulated voltage limitations

4.2.2 System environment

A parameter set changeover function involving 8 different parameter sets hasbeen implemented. The request is made via the PLC. They are predominantlycontroller and filter data that can be switched over as a function of parameterset.

Data which are assigned to specific parameter sets are identified by an [n] in thestring code.

Parameter set assignments can be found in the parameter table (Section 4.15)in the “Attribute index” column with entries 0...7.

Parameter setchangeover


4.2 Functions

08.99

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4.3 Closed-loop velocity control

4.3.1 Velocity adaptation/feedforward control

The NC drive transfer interface is normalized to the maximum velocity set indata MD 5401: DRIVE_MAX_SPEED.

5401 DRIVE_MAX_SPEED Cross ref.: –

Maximum useful velocity Relevant for: HLA

Protection level: 3/3

Unit: mm/min

Default: 0.0

Minimum: 0.0

Maximum: 120 000.0

Data type: FLOAT

Effective: Power On

The velocity limit is defined by the settings in MD 5440:POS_DRIVE_SPEED_LIMIT and MD 5441: NEG_DRIVE_SPEED_LIMIT, butnot with MD 5401: DRIVE_MAX_SPEED.

5004 CTRL_CONFIG Cross ref.: –

Configuration structure Relevant for: HLA


Unit: HEX

Default: 1000

Minimum: 0

Maximum: 1000

Data type: UNS.WORD

Effective: Power On

Velocity setpoints are input in the position controller cycle. In order to prevent rigorous drive positioning motions at the beginning of eachposition controller cycle, the current and previous velocity setpoint are interpo-lated linearly in the drive.

Bit 12=0: No interpolation, velocity setpoint changes only in the position controller cycle.

Bit 12=1: Linear interpolation of velocity setpoint over one position controller cycle. The default setting is active.

Velocity setpoint

Velocity setpoint interpolation deactivated

Time

Velocity setpoint from theNC

Velocity setpoint active indrive

Position controller cycle

Velocity setpoint

Velocity setpoint interpolation activated

Time

Position controller cycle

Fig. 4-3 Velocity setpoint interpolation

Velocity setpointadaptation

Velocity setpointinterpolation



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02.99


Due to the complexity of applying velocity setpoint filters, no generally applica-ble, definitive guidelines for their use can be given here. However, criteria forselecting filters and their parameters are defined below.

The purpose of velocity setpoint filters is to adapt the velocity-controlled drivegrouping to the higher-level position control loop. Band-stop and low-pass filters(PT2/PT1) are available.

The task of a filter is to

smooth the control response characteristic,

dampen mechanical resonance and

symmetrize axes with different dynamic responses, especially the responseof interpolating axes.

Note

Low-pass filters can be employed on interpolating axis groupings to compen-sate for differences in dynamic response in velocity control loops.

The total equivalent time constant (equivalent time constant of velocity controlloop + equivalent time constant of velocity setpoint filter) must be set to anidentical value for all mutually interpolating axes.

The input of damping values close to the minimum input limits results in over-shoots up to a factor of 2 in the time range.

5500 NUM_SPEED_FILTERS [n] 0...7 index of the parameter set Cross ref.: –

No. of velocity filters0: No velocity filter active1: Velocity filter activated

Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD

Effective: Immediately

5501 SPEED_FILTER_TYPE [n] 0...7 index of the parameter set Cross ref.: –

type of velocity filter Bit 0= 0: Low-pass (see MD 5502, MD 5506, MD 5507)

1: Band-stop (see MD 5514 – MD 5516, MD 5520)Bit 8= 0: PT2 low-pass (see MD 5506, MD 5507)

1: PT1 low-pass (see MD 5502)

Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 257

Data type: UNS.WORD


5502 SPEED_FILTER_1_TIME [n] 0...7 index of the parameter set Cross ref.: –

PT1 time constant for velocity filter 1 Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: 0.0

Maximum: 500.0

Data type: FLOAT


The filter is activated via MD 5500 (1) and deactivated via (0). The default set-ting is deactivated. The type of velocity filter can be parameterized in MD 5501 as a PT1 or PT2 low-pass or as a band-stop filter. The key data forthe filter are set in MD 5502 to MD 5520.

The filter is deactivated if machine data MD 5502 is set to 0.

Velocity setpointfilters



02.99



5506 SPEED_FILTER_1_FREQUENCY [n] 0...7 index of the parameter set Cross ref.: –

PT2 natural frequency for velocity filter 1 Relevant for: HLA


Unit: Hz

Default: 2000.0

Minimum: 10.0

Maximum: 8000.0

Data type: FLOAT


5507 SPEED_FILTER_1_DAMPING [n] 0...7 index of the parameter set Cross ref.: –

PT2 damping for velocity filter 1 Relevant for: HLA


Unit: –

Default: 0.7

Minimum: 0.2

Maximum: 1.0

Data type: FLOAT


Setting the machine data to a value of < 10 Hz as the low-pass natural fre-quency deactivates the filter.

Note

With reference to interpolating axes, please read Section 3.9.7.


Absolutevalue[dB]

log f [Hz]102 103

Phase frequencycurve

Phase angle[degrees]

log f [Hz]102 103

0.2

1.0

0.5

1.00.5

0.2

Natural frequency

–20

–30

–10

–303

10

–90

–180

0

90

180

Fig. 4-4 Low-pass filter (PT2) operation at natural frequency (MD 5506) of 1000 Hz andvariations in damping (MD 5507) of 0.2, 0.5 and 1.0



02.99


5514 SPEED_FILTER_1_SUPPR_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Band-stop filter blocking frequency for velocity filter 1 Relevant for: HLA


Unit: Hz

Default: 3500.0

Minimum: 10.0

Maximum: 7999.0

Data type: FLOAT


5515 SPEED_FILTER_1_BANDWIDTH [n] 0...7 index of the parameter set Cross ref.: –

Band-stop filter bandwidth for velocity filter 1 Relevant for: HLA


Unit: Hz

Default: 500.0

Minimum: 5.0

Maximum: 7999.0

Data type: FLOAT


Note

The bandwidth must be smaller or equal to 2 x MD 5514 x MD 5520.

5516 SPEED_FILTER_1_BW_NUMERATOR [n] 0...7 index of the parameter set Cross ref.: –

Numerator bandwidth for velocity filter 1 Relevant for: HLA


Unit: Hz

Default: 0.0

Minimum: 0.0

Maximum: 7999.0

Data type: FLOAT


Note

Setting a value of 0 (MD 5516) initializes the filter as an undamped band-stop.

The value set in MD 5516 must not exceed twice the value set in MD 5515.

5520 SPEED_FILTER_1_BS_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Band-stop filter natural frequency for velocity filter 1 Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 1.0

Maximum: 141.0

Data type: FLOAT


The natural frequency for the general band-stop is set in MD 5520 as a percent-age of MD 5514 (blocking frequency).

Note

Setting MD 5520=100% initializes the filter as an undamped band-stop.

The natural frequency in Hz of the filter must be less than the reciprocal valuefo two velocity controller cycles (MD 55200.01MD 5514<1/(2MD 500131,25 µs).



02.99



2000 Hz1000 Hz500 Hz

2000 Hz1000 Hz500 Hz


Absolutevalue[dB]

log f [Hz]102 103



log f [Hz]102 103

–20

–30

–10

–303

10

–90

–180

0

90

180

Fig. 4-5 Frequency response of undamped band-stop with a bandwidth of 500 Hz andvariations in blocking frequency (MD 5514) of 500 Hz, 1000 Hz, 2000 Hz

100 Hz

500 Hz1000 Hz

100 Hz

500 Hz

1000 Hz


Absolutevalue[dB]

log f [Hz]102 103



log f [Hz]102 103

–20

–30

–10

–303

10

–90

–180

0

90

180

Fig. 4-6 Frequency response of undamped band-stop at a blocking frequency of 1000Hz and variations in bandwidth (MD 5515) of 100 Hz, 500 Hz, 1000 Hz. The bandwidth is the difference between the two frequencies with 3 dB drop inamplitude.



02.99


150

250

0

0

150

250


Absolutevalue[dB]

log f [Hz]102 103



log f [Hz]102 103

–20

–30

–10

–303

10

–90

–180

0

90

180

Fig. 4-7 Band-stop behavior with bandwidth of 500 Hz, blocking frequency of 1000 Hzand variation in numerator bandwidth (MD 5516) of 0, 150 and 250 Hz.

1000

707

1414

707

1414

707

1414

1000


Absolutevalue[dB]

log f [Hz]102 103



log f [Hz]102 103

–20

–30

–10

–303

10

–90

–180

0

90

180

Fig. 4-8 Frequency response of general band-stop at a blocking frequency of fz=1000Hz, bandwidth fBn=500 Hz, numerator bandwidth fBz=0 Hz and variation innatural frequency of (MD 5520) fn=70.7 %, 1000 % and 141.4 %



02.99



The velocity setpoint is limited in the positive and negative directions.

Note

The maximum rapid traverse velocity of the drive (G0 function) is determinedby NC machine parameter 32000.

5420 DRIVE_MAX_SPEED_SETUP Cross ref.: –

Max. velocity for setup mode Relevant for: HLA


Unit: mm/min

Default: 10.0

Minimum: 0.0

Maximum: 120 000.0

Data type: FLOAT


5440 POS_DRIVE_SPEED_LIMIT Cross ref.: –

Positive velocity setpoint limit Relevant for: HLA


Unit: mm/min

Default: 0.0

Minimum: 0.0

Maximum: 120 000.0

Data type: FLOAT


5441 NEG_DRIVE_SPEED_LIMIT Cross ref.: –

Negative velocity setpoint limit Relevant for: HLA


Unit: mm/min

Default: 0.0

Minimum: 0.0

Maximum: 120000.0

Data type: FLOAT


With a differential cylinder, the physically possible velocities for piston travel-outand travel-in are asymmetrical. For this reason, it is advisable to set asymmetri-cal limitations. A ZK3 message (can be interrogated via PLC) is activated whenthe limitation is violated.

If setup mode is selected, then the velocity setpoint is set to the value in MD5420 for both directions. The velocity setpoint limitation is calculated as part ofthe “Calculate drive model data” operation and MD 5440 and MD 5441 presetaccordingly.

To protect mechanical components against excessive wear and damage, thedrive acceleration rate setpoints can be limited by the NC. The linear interpola-tion of velocity setpoints (cf. MD 5522: SPEED_FIPO_TYPE; velocity setpointinterpolation) ensures that the drive accelerates at the rate specified by the con-trol. A function for limiting the acceleration rate in the drive has not been imple-mented. (A braking ramp is operative only if the velocity controller is disabled,see MD 5402: SPEED_CTRL_DISABLE_STOPTIME).

The controlled system gain should be entered in MD 5435 after “Calculate drivemodel data” and not altered unless it is incorrect. The value in MD 5435 is thereference for the P gain of the velocity controller.

5435 CONTROLLED_SYSTEM_GAIN [n] 0...7 index of the parameter set Cross ref.: –

Controlled system gain Relevant for: HLA


Unit: mm/Vmin

Default: 0.0

Minimum: 0.0

Maximum: 20000.0

Data type: FLOAT


Velocity setpointlimitation

Accelerationlimitation

Controlled systemgain



02.99


5460 FRICTION_COMP_GRADIENT Cross ref.: –

Gradient of friction compensation characteristic Relevant for: HLA


Unit: %

Default: 0.0

Minimum: 0.0

Maximum: 400.0

Data type: FLOAT


5461 FRICTION_COMP_OUTPUT_RANGE Cross ref.: –

Effective range of friction compensation (at output) Relevant for: HLA


Unit: %

Default: 0.1

Minimum: 0.1

Maximum: 10.0

Data type: FLOAT


In order to reduce the effects of friction, the characteristic gradient is madesteeper around the zero point in the flow feedforward control path (see Fig. 4-2).The differential pressure is thus boosted with the velocity setpoint sign. Fig. 4-9shows an example of this characteristic and the mode of action of the associ-ated machine data (see also Section 2.3.1 and Appendix A).

100%

100%

–100%

–100%

MD 5460

MD 5461

Input

Output

– MD 5461

Fig. 4-9 Friction compensation characteristic; see also static friction injectionSection 4.4.2.

4.3.2 Velocity controller

Sampling time with which the velocity control loop is calculated.

5001 SPEEDCTRL_CYCLE_TIME Cross ref.: –

Velocity controller cycle Relevant for: HLA


Unit: 31.25 µs

Default: 4

Minimum: 2

Maximum: 16

Data type: UNS.WORD

Effective: Power On

Short cycle: Good dynamic response, but measurement noise from actual velocity increases.

Long cycle: Poor dynamic response, actual velocity values are not noisy

Friction

Velocity controllercycle



02.99



Recommended setting: Increase cycle time for measuring system with wide scale graduations or wherederivative action time of D component is large.

Adaptation of the P and D components is recommended in cases where thenatural frequency of the servo solenoid valve is higher than that of the drive.

5413 SPEEDCTRL_ADAPT_ENABLE Cross ref.: –

Selection of velocity controller adaptation Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


Precondition: Adaptation can be selected only zero calibration of cylinder piston,see Section 3.9.4.

The adaptation is activated (bit 0=1) or deactivated (bit 0=0) depending on thesetting in MD 5413: SPEEDCTRL_ADAPT_ENABLE. If adaptation is deacti-vated, machine data MD 5407: SPEEDCTRL_GAIN and MD 5430:SPEEDCTRL_PT1_TIME apply.

Adaptation ON (see Fig. 4-10)

MD 5406: SPEEDCTRL_GAIN_A and MD 5408: SPEEDCTRL_GAIN_B areprogrammed to define the P gain and MD 5431:SPEEDCTRL_DIFF_TIME_A and MD 5433: SPEEDCTRL_DIFF_TIME_Bto define the derivative-action time (D component) at the A and B ends ofthe cylinder.

MD 5407: SPEEDCTRL_GAIN and MD 5432: SPEEDCTRL_DIFF_TIMEact on the position set in MD 5160: PISTON_POS_MIN_NAT_FREQ.

Adaptation OFF

MD 5407: SPEEDCTRL_GAIN and MD 5432: SPEEDCTRL_DIFF_TIMEare active over the entire range,

The natural frequency of the drive varies as a function of distance. Extreme val-ues occur at the two limits and in the approximate center (MD 5160) of the tra-versing range. It may therefore be useful to adapt the velocity controller position(P and D components), with the extreme range limits specified as interpolationpoints.

The adaptation function can be activated or deactivated.

If the piston zero has not been calibrated, the adaptation will not be operative,even if it is activated.

When adaptation is active, the P gain and D-action component of the velocitycontroller are interpolated linearly between two points.

“Calculate controller data” alters the settings for the controllers and the adapta-tion selection.

Adaptation of P and D components



02.99


MD 5160

P component

Piston position

MD 5407

0 MD 5134

MD 5408

MD 5406

MD 5160

Derivative-action time

Piston position

MD 5433

0 MD 5134

MD 5431

MD 5432

MD 5160

Naturalfrequencyof drive

Piston position

MD 5163

0 MD 5134

MD 5164MD 5162

Piston endCylinder A end

Piston endCylinder B end

(min. natural frequency) (piston stroke)

A B A B

Fig. 4-10 Adaptation

5406 SPEEDCTRL_GAIN_A [n] 0...7 index of the parameter set Cross ref.: –

P gain of velocity controller A Relevant for: HLA


Unit: %

Default: 0.0

Minimum: –100.0

Maximum: 1000.0

Data type: FLOAT


5407 SPEEDCTRL_GAIN [n] 0...7 index of the parameter set Cross ref.: –

P gain of velocity controller Relevant for: HLA


Unit: %

Default: 0.0

Minimum: –100.0

Maximum: 1000.0

Data type: FLOAT


5408 SPEEDCTRL_GAIN_B [n] 0...7 index of the parameter set Cross ref.: –

P gain of velocity controller B Relevant for: HLA


Unit: %

Default: 0.0

Minimum: –100.0

Maximum: 1000.0

Data type: FLOAT


P component



02.99



A negative P gain setting may be useful for oscillation damping. Negative gainsettings are permissible. The gain is specified in relation to the drive servo gainsetting. 100 % means that the full rated valve voltage is output as the P compo-nent with a setpoint/actual value difference corresponding to maximum velocity(MD 5440: POS_DRIVE_SPEED_LIMIT, MD 5441:NEG_DRIVE_SPEED_LIMIT).

The P gain set in MD 5407 SPEEDCTRL_GAIN is referred to the controlledsystem gain set in MD 5435: CONTROLLED_SYSTEM_GAIN.

5409 SPEEDCTRL_INTEGRATOR_TIME [n] 0...7 index of the parameter set Cross ref.: –

Reset time of velocity controller Relevant for: HLA


Unit: ms

Default: 50.0

Minimum: 0.0

Maximum: 2000.0

Data type: FLOAT


The integral-action component can be deactivated by setting the reset time tozero. With a negative P gain setting, the reset time is interpreted as a negativevalue so that the compensation always acts as negative feedback.

The integrator can be activated/deactivated via the PLC. The current status isreturned to the PLC.

5421 SPEEDCTRL_INTEGRATOR_FEEDBK [n] 0...7 index of the parameter set Cross ref.: –

Time constant of integrator feedback Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: 0.0

Maximum: 1000.0

Data type: FLOAT


The integrator of the velocity controller loop is reduced to a 1st-order low-passaction with the configured time constant via a weighted feedback.

Effect:The output of the velocity controller integrator is limited to a value propor-tional to the setpoint/actual value deviation (steady-state proportional ac-tion).

Applications:Machining motions at position setpoint zero and dominant static friction canbe suppressed but result in a permanent distance-to-go, e.g. oscillation ofthe positon controlled axis at zero speed (stick-slip effect) or overshooting inµm-step method.

Setting note:Optimize this data starting at a high value until you find the bestcompromise.

If the time constant integrator feedback 1 ms is set, feedback is disabled.

I component

Integrator feedback



02.99


Velocity below which the integrator feedback becomes operative.

5422 FEEDBK_SPEED_THRESHOLD Cross ref.: –

Integrator feedback velocity threshold Relevant for: HLA


Unit: mm/min

Default: 10.0

Minimum: 0.0

Maximum: 120000.0

Data type: FLOAT


The integrator feedback function is mainly used when static friction problemsare encountered, i.e. so as to suppress undesirable movements caused bystatic friction (slip-stick effect) in position-controlled operation and at zero speed.

MD 5422 can be set to ensure that the integrator feedback is activated only atlow velocity setpoints and stabilizes the axis at zero speed. At high velocities,however, the effect of the I component is not restricted.

A derivative-action component (acceleration feedback) is implemented in thecontroller in addition to the P component. This D component lies in the feedbackbranch and is set as a function of the derivative-action time. It may be a nega-tive or positive setting. No D component is active if the D-action time is set tozero.

5430 SPEEDCTRL_PT1_TIME [n] 0...7 index of the parameter set Cross ref.: –

Velocity controller smoothing time constant Relevant for: HLA


Unit: ms

Default: 0.25

Minimum: 0.25

Maximum: 100.0

Data type: FLOAT


5431 SPEEDCTRL_DIFF_TIME_A [n] 0...7 index of the parameter set Cross ref.: –

Velocity controller A derivative-action time (D component) Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: –100.0

Maximum: 100.0

Data type: FLOAT


5432 SPEEDCTRL_DIFF_TIME [n] 0...7 index of the parameter set Cross ref.: –

Velocity controller derivative-action time (D component) Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: –100.0

Maximum: 100.0

Data type: FLOAT


5433 SPEEDCTRL_DIFF_TIME_B [n] 0...7 index of the parameter set Cross ref.: –

Velocity controller B derivative-action time (D component) Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: –100.0

Maximum: 100.0

Data type: FLOAT


Similar to the P component setting, it is possible to set a D component at the Aand B ends of the cylinder.

Since precise differentiation is not possible, an additional denominator compo-nent must be provided. This component is set by means of a smoothing timeconstant (MD 5430: SPEEDCTRL_PT1_TIME). If the D component is deacti-vated, then the smoothing constant also ceases to function.

Integrator feedback threshold

D component (acceleration feedback)



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5414 SPEEDCTRL_REF_MODEL_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Natural frequency of reference model Relevant for: HLA


Unit: Hz

Default: 150.0

Minimum: 0.0

Maximum: 1000.0

Data type: FLOAT


5415 SPEEDCTRL_REF_MODEL_DAMPING [n] 0...7 index of the parameter set Cross ref.: –

Reference model damping Relevant for: HLA


Unit: –

Default: 0.9

Minimum: 0.4

Maximum: 1.0

Data type: FLOAT


The dynamic response of the velocity control loop to control commands withoutan I component in the velocity controller is simulated in the reference model. Inthe ideal case of exact simulation, there is no deviation after the setpoint/actualvalue comparison on the integrator under no-load conditions. In practice, veloc-ity overshoots in the response to control commands can be reduced in this way.

The reference model is parameterized by settings for natural frequency(MD5414) and damping (MD 5415).

Controller optimization reference model:

Precondition: I-component=0 (MD 5409=0)

Objective: Overshooting in response to setpoint changes caused by the I component can be reduced by means of the reference model.

Procedure:

1. Set I-action gain (MD 5406: SPEEDCTRL_GAIN_A)(MD 5407: SPEEDCTRL_GAIN)(MD 5408: SPEEDCTRL_GAIN_B)

to zero (make note of original values!).

2. Record frequency response of the closed (adjusted and optimized) velocitycontrol loop.

3. Adjust the frequency response of the reference model by matching the filternatural frequency (MD 5414) and filter damping (MD 5415) to the frequencyresponse recorded in point 2..In the ideal case of exact simulation, there is no deviation after the setpoint/actual value comparison on the integrator.

4. Enter I-action gain as calculated in the preceding optimization step.

Reference model



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Two control output filters have been implemented. As compared to the currentsetpoint filter on electrical drives, the scope of functions has been extended bythe general band stop.

5200 NUM_OUTPUT_VCTRL_FILTERS [n] 0...7 index of the parameter set Cross ref.: –

Number of control output filters for velocity controller Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 2

Data type: UNS.WORD


The number of control output filters in the velocity controller is set in MD 5200.The default setting is “deactivated”. Band-stop and 2nd-order low pass filterscan be selected and set in MD 5201: OUTPUT_FILTER_CONFIG.

Table 4-1 Selection of number of control output filters in velocity controller

0 No control output filter active

1 Filter 1 active

2 Filters 1 and 2 active

Input of configuration of 2 control output filters. A selection of band-stops andlow passes is available. The parameters that can be set for each filter type mustbe entered in the relevant machine data.

Note

Before the filter type is configured, the corresponding filter machine data mustbe parameterized.

5201 OUTPUT_VCTRL_FILTER_CONFIG [n] 0...7 index of the parameter set Cross ref.: –

Control output filter type in velocity controller Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 3

Data type: UNS.WORD


Table 4-2 Control output filter type in velocity controller

1st filter Bit 00 Low pass (see MD 5202/5203)

1st filter Bit 01 Band-stop (see MD 5210/5211/5212)

2nd filter Bit 10 Low pass (see MD 5204/5205)

2nd filter Bit 11 Band-stop (see MD 5213/5214/5215)

Table 4-3 Filter combinations

Filter 2 Filter 1 MD 5201: OUTPUT_VCTRL_FILTER_CONFIG

PT2 PT2=0 0

PT2 BS=1 1

BS PT2 2

BS BS 3

Control output,velocity controller



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5202 OUTPUT_VCTRL_FIL_1_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Natural frequency of control output filter 1 in velocity controller

Relevant for: HLA


Unit: Hz

Default: 1000.0

Minimum: 10.0

Maximum: 8000.0

Data type: FLOAT


5204 OUTPUT_VCTRL_FIL_2_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Natural frequency of control output filter 2 in velocity control-ler

Relevant for: HLA


Unit: Hz

Default: 1000.0

Minimum: 10.0

Maximum: 8000.0

Data type: FLOAT


The filter key data are defined in MD 5202, MD 5205 and MD 5210 to MD 5215.

Input of natural frequency for control output filters 1...2 (PT2 low-pass) in thevelocity controller.The filters are activated in MD 5200: NUM_OUTPUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

5203 OUTPUT_VCTRL_FIL_1_DAMP [n] 0...7 index of the parameter set Cross ref.: –

Damping of control output filter 1 in velocity controller Relevant for: HLA


Unit: –

Default: 1.0

Minimum: 0.05

Maximum: 1.0

Data type: FLOAT


5205 OUTPUT_VCTRL_FIL_2_DAMP [n] 0...7 index of the parameter set Cross ref.: –

Damping of control output filter 2 in velocity controller Relevant for: HLA


Unit: –

Default: 1.0

Minimum: 0.05

Maximum: 1.0

Data type: FLOAT


Input of damping for control output filters 1...2 (PT2 low-pass) in the velocitycontroller. The filters are activated in machine data MD 5200: NUM_OUT-PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

5210 OUTPUT_VCTRL_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Blocking frequency of control output filter 1 in velocity controller

Relevant for: HLA


Unit: Hz

Default: 3500.0

Minimum: 1.0

Maximum: 7999.0

Data type: FLOAT


5213 OUTPUT_VCRTL_FIL_2_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Blocking frequency of control output filter 2 in velocity con-troller

Relevant for: HLA


Unit: Hz

Default: 3500.0

Minimum: 1.0

Maximum: 7999.0

Data type: FLOAT


Input of blocking frequency for control output filters 1...2 (bandstop) in the veloc-ity controller. The filters are activated in machine data MD 5200: NUM_OUT-PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.



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5211 OUTPUT_VCTRL_FIL_1_BW [n] 0...7 index of the parameter set Cross ref.: –

Bandwidth of control output filter 1 in velocity controller Relevant for: HLA


Unit: Hz

Default: 500.0

Minimum: 5.0

Maximum: 7999.0

Data type: FLOAT


5214 OUTPUT_VCTRL_FIL_2_BW [n] 0...7 index of the parameter set Cross ref.: –

Bandwidth of control output filter 2 in velocity controller Relevant for: HLA


Unit: Hz

Default: 500.0

Minimum: 5.0

Maximum: 7999.0

Data type: FLOAT


Input of –3dB bandwidth for control output filters 1...2 (bandstop) in the velocitycontroller.

The filters are activated in machine data MD 5200: NUM_OUT-PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

5212 OUTPUT_VCTRL_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –

Numerator bandwidth of control output filter 1 in velocitycontroller

Relevant for: HLA


Unit: Hz

Default: 0.0

Minimum: 0.0

Maximum: 7999.0

Data type: FLOAT


5215 OUTPUT_VCTRL_FIL_2_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –

Numerator bandwidth of control output filter 2 in velocity controller

Relevant for: HLA


Unit: Hz

Default: 0.0

Minimum: 0.0

Maximum: 7999.0

Data type: FLOAT


Input of numerator bandwidth for control output filters 1...2 (damped bandstop)in the velocity controller. Setting a value of 0 initializes the filter as an undampedband-stop.

The filters are activated in machine data MD 5200: NUM_OUT-PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

4.3.3 Dynamic Stiffness Control (DSC)

The DSC (Dynamic Stiffness Control) function is supported, allowing higher Pgain settings in the position controller. The function is implemented in the sameway as on an electrical drive. It is also activated via the control system (as on anelectrical drive).

DSC



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4.4 Closed-loop force control

Pressure sensors must be installed

Force limitation and/or static friction injection activated (MD 5241: FORCECTRL_CONFIG)

Piston position must have been calibrated (see Section 3.9.4)

PA

FB

DF=Fpiston=Factual

FA

ABAA

Measured value sensing

A B

PB

ABAA

Force controller

FA FB

MD 5131MD 5132

MD 5131MD 5133

Fset

–

–

The letters have the fol-lowing meaning:A: AreaP: PressureF: Force

Cylinders

Fig. 4-11 Actual force measurement sensing

To start up the force controller, it is possible to redirect the measuring functionsand function generator from the velocity controller to the force controller by set-ting bit 8 in MD 5650. In this setting, velocity setpoints are interpreted as forcesetpoints in units of kN. This mode is deactivated by resetting MD 5650, bit 8(mm/min → kN).

Force limitation is required

in certain machining processes for which the “Travel to fixed stop” functionmust be implemented or

to work material in the machining of force profiles.

This compensation function is needed to compensate the effects of static fric-tion occurring when the traversing direction changes (reduction of contour er-rors, see e.g. circularity test).

Preconditions

Start-up of forcecontroller

Force limitation

Static friction compensation



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Input of configuration for force controller:

5241 FORCECTRL_CONFIG [n] 0...7 index of the parameter set Cross ref.: –

Configuration of force controllerBit 0= 0: Force limitation 1 from

1: Force limitation 1 onBit 1= 0: Static friction injection off

1: Static friction injection onBit2= 0: Force limitation 2 offBit2= 1: Force limitation 2 on

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: 6

Data type: UNS.WORD


If a pressure sensor is installed and connected for the pressures at A and B, theforce limitation and/or static friction injection functionsin MD 5241 can be switched on.

Before the force limitation and/or static friction injection is activated, the associ-ated machine data for force limitation (MD 5230, MD 5231)or friction force (MD 5234, MD 5235) should be set. These data may contain theforce of weight values and might not be preset correctly by the defaults.

If the cylinder load changes and the force of weight must be held by the cylin-der, then the static friction injection function cannot be utilized, as the values inMD 5234 and MD 5235 vary as a function of load.

Static friction injection (MD 5241 bit 1=1), see Section 4.4.2.

Force limitation 1 (MD 5241 bit 0=1)

Force limitation 1 is always effective, even without FFA (NC function “Travelto fixed stop”). The force limit is specified in MD 5230. If FFA is active, thelowest force limitation always takes effect (MD 5230 or MD 37010 or value from FXST[x]). Reference value (100% value) of forcelimit for NC is MD 5725.

If the force level falls below the specified limit, the velocity controller be-comes active again, even with FFA. This can cause faults with FFA. Athigher velocities, this can also cause continuous alternation between theforce and velocity controller. This mode is therefore only suitable for low ve-locities (<0.1 maximum velocity).

Force limitation 2 (MD 5241 bit 2=1)

Force limitation 2 becomes active when the force limit value is exceededand FFA is active. In each case, the lowest force limitation becomes active(MD 5230 or MD 3710 or value from FXST[x]). Reference value (100%value) of force limit for NC is MD 5725.

Force limitation remains active until the function FFA is deactivated, even ifthe force has already fallen below the current force limitation.

Force controllerconfiguration



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FFA

t0

Fcontr. on

t0

F

t0

Mode

Fact

Flimit

Fig. 4-12 Force limitation 2

Deselection of closed-loop force control by deactivating function “Travel to fixedstop” bit.

4.4.1 Force limitation

Force limitation tolerance band (plus/minus) about force of weight and weightforce limitation.

5230 FORCE_LIMIT_THRESHOLD [n] 0...7 index of the parameter set Cross ref.: –

Force limitation tolerance band about weight Relevant for: HLA


Unit: N

Default: 10000.0

Minimum: 0.0

Maximum: 100000000.0

Data type: FLOAT


5231 FORCE_LIMIT_WEIGHT [n] 0...7 index of the parameter set Cross ref.: –

Weight force limitation Relevant for: HLA


Unit: N

Default: 0.0

Minimum: –100000000.0

Maximum: 100000000.0

Data type: FLOAT


If a pressure sensor is installed and connected for the pressures at A and B, theforce limitation in MD 5241 can be activated.

The force controller then ensures that the cylinder force is limited to therelevant values if it is threatening to exceed the value set in MD 5230 plus forceof weight (MD 5231) or to drop below the force of weight value (MD 5231) minusthe setting in MD 5230.

Since only the cylinder force is measured and regulated, it may be necessary toallow for the force of weight in MD 5231 and the friction force in MD 5230.

An additional force limitation value with the same effect as MD 5230 can be in-put by the NC, e.g. on travel to fixed stop. The lower of the two force limitationvalues is then applied.



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4.4.2 Static friction injection

If a pressure sensor is installed and connected for the pressures at A and B, thestatic friction injection function in MD 5241 can be activated.

Static force injection should not be activated if the cylinder must hold a varyingforce of weight. In addition, the offset of the valve manipulated voltage and thepiston position must already have been adjusted. Machine data MD 5232...MD5235 can be adjusted by means of a circularity test.

Velocity below which standstill and thus static friction is detected.

5232 STICTION_SPEED_THRESHOLD Cross ref.: –

Velocity threshold for static friction Relevant for: HLA


Unit: mm/min

Default: 10.0

Minimum: 0.0

Maximum: 500.0

Data type: FLOAT


The force controller ensures that the force is limited to the value set in MD 5234or MD 5235 when the velocity drops below the setting in MD 5232 for as long asthe drive is stationary.

Which of the two force setpoints is applied (MD 5234 or MD 5235) is determinedby the sign of the velocity setpoint.

The force controller is deactivated just before the setpoint is reached via thecutoff limit (MD 5233) to prevent overshoots occurring during servo solenoidvalve actuation.

5233 STICTION_COMP_THRESHOLD Cross ref.: –

Cutoff limit static friction Relevant for: HLA


Unit: %

Default: 40.0

Minimum: 3.0

Maximum: 100.0

Data type: FLOAT


The force controller is deactivated just before the setpoint is reached via thecutoff limit (MD 5233) to prevent overshoots occurring during servo solenoidvalve actuation.

If MD 5233 is set to 100%, then the force controller is not switched off until theforce setpoint (MD 5234 or MD 5235) is reached or unless the drive moves be-forehand. This setting results in overshoots in the actual velocity value.

Velocity threshold

Cutoff limit



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The cylinder friction force at a positive velocity can be set in MD 5234.

5234 STICTION_FORCE_POS Cross ref.: –

Friction force at velocity >0 Relevant for: HLA


Unit: N

Default: 100.0

Minimum: –100000000.0

Maximum: 100000000.0

Data type: FLOAT


Allowance must be made for the force of weight applied to the cylinder in MD5234 (e.g. with a cylinder mounting position other than 0 degrees, MD 5151).The value to be set can be read in MD 5708 when the cylinder is moved slowly(e.g. in JOG mode) in the positive direction.

If the force of weight applied to the cylinder varies as a function of load, thenstatic force injection cannot be utilized.

5235 STICTION_FORCE_NEG Cross ref.: –

Friction force at velocity <0 Relevant for: HLA


Unit: N

Default: –100.0

Minimum: –100000000.0

Maximum: 100000000.0

Data type: FLOAT


Allowance must be made for the force of weight applied to the cylinder in MD5235 (e.g. with a cylinder mounting position other than 0 degrees, MD 5151).The value to be set can be read in MD 5708 when the cylinder is moved slowly(e.g. in JOG mode) in the negative direction.

If the force of weight applied to the cylinder varies as a function of load, thenstatic force injection cannot be utilized.

4.4.3 Force controller

Factor for setting the feedforward control gain in the force controller.

5247 FORCE_FFW_WEIGHT Cross ref.: –

Feedforward control factor for force controller Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 0.0

Maximum: 120.0

Data type: FLOAT


Operative only if force limitation or static friction injection is activatedin MD 5241.

The more accurate the feedforward control setting, the more effective the forcelimitation at high velocities.

An excessively high setting can result in continuous switching between forceand velocity controllers.

The area adaptation (MD 5462 and MD 5463) and controlled system gain (MD5435) are taken into account by the feedforward control.

Cylinder frictionforce

Feedforward control gain offorce controller



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5240 FORCECONTROLLED_SYSTEM_GAIN Cross ref.: –

Controlled system gain of force controller Relevant for: HLA


Unit: N/V

Default: 0.0

Minimum: 0.0

Maximum: 1000000000.0

Data type: FLOAT


MD 5240 contains the controlled system proportional gain for the force controlloop.

Since the force control loop has an integral action, a unit integrator (I-action timeof 1 second) was subtracted from the controlled system to calculate the gain.

MD 5240 is preset by the “Calculate drive model data” routine.

The controlled system gain depends on the volume of oil in the cylinder and therated volumetric flow of the servo solenoid valve. The value should not gener-ally be altered.

The value in MD 5240 is the reference for the P gain of the force controller.

MD 5240 makes allowance for the effects of geometric dimensions.

The effect of the valve dynamic response is taken into account in MD 5242,which means that the same gain value can always be set for an identical valvedynamic response on different cylinders.

5242 FORCECTRL_GAIN [n] 0...7 index of the parameter set Cross ref.: –

P gain of force controller Relevant for: HLA


Unit: –

Default: 0.0

Minimum: 0.0

Maximum: 10000.0

Data type: FLOAT


If force limitation and/or static friction injection is activated in MD 5241, the Pgain of the force controller is entered in this machine data.

The P-gain reference is MD 5240 containing a value representing the overalleffects of geometric dimensions.

The effect of the valve dynamic response is taken into account in MD 5242,which means that the same gain value can always be set for an identical valvedynamic response on different cylinders.

5243 FORCECTRL_GAIN_RED Cross ref.: –

Reduction of force controller P component Relevant for: HLA


Unit: %

Default: 40.0

Minimum: 0.1

Maximum: 100.0

Data type: FLOAT


Controlled systemgain of force controller

P componentof force controller



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If force limitation and/or static friction injection are activated in MD 5241, thereduction in the force controller P gain in response to large setpoint/actual valuedeviations (large-signal operation) is entered in MD 5243. The P component ofthe force controller must be reduced since the dynamic limitations of the actua-tor in large-signal operation also reduce the potential dynamic response of thecontrol loop.

Small-signal operation is set in MD 5242.

The factor in MD 5243 specifies as a percentage to what value a P componentof 10 V is reduced.

5244 FORCECTRL_INTEGRATOR_TIME [n] 0...7 index of the parameter set Cross ref.: –

Reset time of force controller Relevant for: HLA


Unit: ms

Default: 40.0

Minimum: 0.0

Maximum: 2000.0

Data type: FLOAT


If force limitation and/or static friction injection is activated in MD 5241, the resettime of the force controller is entered in this machine data.

Enter a value of 0 for the reset time deactivates the I-action component.

5245 FORCECTRL_PT1_TIME [n] 0...7 index of the parameter set Cross ref.: –

Force controller smoothing time constant Relevant for: HLA


Unit: ms

Default: 0.5

Minimum: 0.25

Maximum: 100.0

Data type: FLOAT


5246 FORCECTRL_DIFF_TIME [n] 0...7 index of the parameter set Cross ref.: –

D-action time of force controller Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: –10000.0

Maximum: 10000.0

Data type: FLOAT


If force limitation and/or static friction injection is activated in MD 5241, asmoothing time constant of the force controller for derivative action is set in MD5245 and, in addition to the force controller P component (MD 5242), a D-actioncomponent (jerk feedback) in MD 5246.

If the D-action component of the force controller is deactivated (MD 5246), thenthe smoothing function (MD 5245) is also rendered inoperative.

The D-action time setting (MD 5246) can be negative or positive. No D compo-nent is active if the D-action time is set to zero.

I componentof force controller

D componentof force controller



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5260 NUM_FFW_FCTRL_FILTERS [n] 0...7 index of the parameter set Cross ref.: –

No. of force controller feedforward control filters Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


The number of feedforward control filters in the force controller are entered inthis machine data.

Table 4-4 Selection of number of feedforward control filters

0 No feedforward control filter active (default)

1 Filter(s) activated

Note


5261 FFW_FCTRL_FILTER_TYPE [n] 0...7 index of the parameter set Cross ref.: –

Type of feedforward control filter in force controller Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


The type of feedforward control filter in the force controller is entered in this ma-chine data.

Table 4-5 Type of feedforward control filter

Bit 00 Low pass (see MD 5264/5265)

Bit 01 Band-stop (see MD 5268/5269/5270)

5264 FFW_FCTRL_FIL_1_FREQ [n] 0...7 index of the parameter set Cross ref.: –

PT2 natur. freq. feedforward control filter1 Relevant for: HLA


Unit: Hz

Default: 2000.0

Minimum: 10.0

Maximum: 8000.0

Data type: FLOAT



Feedforward con-trol filter for forcecontroller



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5265 FFW_FCTRL_FIL_1_DAMP [n] 0...7 index of the parameter set Cross ref.: –

PT2 damping for feedforward control filter 1 Relevant for: HLA


Unit: –

Default: 0.7

Minimum: 0.2

Maximum: 1.0

Data type: FLOAT


Input of damping for feedforward control filter 1 (PT2 low-pass) in force control-ler.

5268 FFW_FCTRL_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Blocking frequency of feedforward control filter 1 Relevant for: HLA


Unit: Hz

Default: 3500.0

Minimum: 10.0

Maximum: 7999.0

Data type: FLOAT


Input of blocking frequency for feedforward control filter 1 (band-stop) in forcecontroller.

5269 FFW_FCTRL_FIL_1_BW [n] 0...7 index of the parameter set Cross ref.: –

Bandwidth of feedforward control filter 1 Relevant for: HLA


Unit: Hz

Default: 500.0

Minimum: 5.0

Maximum: 7999.0

Data type: FLOAT


Input of –3 dB bandwidth for feedforward control filter 1 (band-stop) in force con-troller.

5270 FFW_FCTRL_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –

Numerator bandwidth feedforward control filter 1 Relevant for: HLA


Unit: Hz

Default: 0.0

Minimum: 0.0

Maximum: 7999.0

Data type: FLOAT


Input of numerator bandwidth for feedforward control filter 1 (damped band-stop) in force controller.

Setting a value of 0 initializes the filter as an undamped band-stop. The valueset in MD 5270 must not exceed twice the value set in MD 5269.



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4.5 Output of manipulated variables

4.5.1 Characteristics compensation

Various non-linear effects of valve or drive can be compensated by means ofcharacteristics. The characteristics are cascaded so that they can be set sepa-rately.

5462 AREA_FACTOR_POS_OUTPUT Cross ref.: –

Piston surface adaptation factor, positive Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 50.0

Maximum: 200.0

Data type: FLOAT


5463 AREA_FACTOR_NEG_OUTPUT Cross ref.: –

Piston surface adaptation factor, negative Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 50.0

Maximum: 200.0

Data type: FLOAT


In order to compensate the direction-dependent controlled-system gain on dif-ferential cylinders, a characteristic with a gradient that is variable as a functionof direction has been implemented. Fig. 4-13 shows an example of this charac-teristic and the mode of action of the associated machine data. In practice, onlyone of the two gradients is weighted with a factor other than 100%. Normally, itis the gradient that causes the cylinder piston to travel out that is weighted witha factor of less than 100% (see also Section 2.3.1 and Appendix A).

100%

100%

–100%

–100%

Output

Input

MD 5462

– MD 5463

–200%

0

Fig. 4-13 Example of piston surface adaptation characteristic

Area adaptation



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Valves with a fine control range are described in Section 4.7. An inverse charac-teristic is applied to compensate the nonlinear characteristic of these valves.The breakpoint on real valves is rounded. For this reason, the breakpoint rangein the compensation characteristic is also rounded. The rounding is imple-mented according to a root characteristic in such a way that the intersectionpoints lie on a continuous tangent; the rounding range can be parameterized.Fig. 4-14 shows an example of this characteristic and the mode of action of theassociated machine data.

The knee point is defined by the percentage for input (voltage) and output(flow).

100%

100%

–100%

–100%

U

Q

MD 5464

MD 5481 MD 5466

MD 5482

MD 5485

MD 5480

MD 5486MD 5465MD 5483

MD 5467

MD 5487

MD 5484MD 5488

MD 5468

(positive/negative)

(positive/negative)

Fig. 4-14 Valve characteristic with breakpoint in zero, fine control and saturation ranges

Valve characteristic with breakpoint in zero range

5480 POS_DUAL_GAIN_COMP_Z_FLOW Cross ref.: –

Knee-point compensation pos. flow in zero range Relevant for: HLA


Unit: %

Default: 0.01

Minimum: 0.01

Maximum: 95.0

Data type: FLOAT


5481 POS_DUAL_GAIN_COMP_Z_VOLT Cross ref.: –

Knee-point compensation pos. voltage in zero range Relevant for: HLA


Unit: %

Default: 0.0

Minimum: 0.0

Maximum: 95.0

Data type: FLOAT


Linearization ofvalve



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5482 DUAL_GAIN_COMP_SMOOTH_Z_R Cross ref.: –

Knee-point compensation rounding in zero range Relevant for: HLA


Unit: %

Default: 0.0

Minimum: 0.0

Maximum: 10.0

Data type: FLOAT


5483 NEG_DUAL_GAIN_COMP_Z_FLOW Cross ref.: –

Knee-point compensation neg. flow in zero range Relevant for: HLA


Unit: %

Default: 0.01

Minimum: 0.01

Maximum: 95.0

Data type: FLOAT


5484 NEG_DUAL_GAIN_COMP_Z_VOLT Cross ref.: –

Knee-point compensation neg. voltage in zero range Relevant for: HLA


Unit: %

Default: 0.0

Minimum: 0.0

Maximum: 95.0

Data type: FLOAT


To calculate the inverse characteristic, a knee-point is defined in the positivezero range of the valve characteristic with MD 5480 and MD 5481 and in thenegative zero range with MD 5483 and MD 5484.

The positive and negative valve flows at the knee-point referred to rated flow(MD 5107) are entered in 5480 and MD 5483 respectively.

The valve voltage at the knee-point referred to the rated valve voltage (MD5109) is entered in MD 5481.

When MD 5481 is set to default zero, there is no breakpoint in the positivezero range.

When MD 5484 is set to default zero, there is not breakpoint in the negativezero range.

The rounding range is parameterized in MD 5482.

Valve characteristic with breakpoint in fine control range

5464 POS_DUAL_GAIN_COMP_FLOW Cross ref.: –

Knee-point compensation pos. flow Relevant for: HLA


Unit: %

Default: 10.0

Minimum: 0.2

Maximum: 95.0

Data type: FLOAT


5465 POS_DUAL_GAIN_COMP_VOLTAGE Cross ref.: –

Knee-point compensation pos. voltage Relevant for: HLA


Unit: %

Default: 10.0

Minimum: 0.2

Maximum: 95.0

Data type: FLOAT


5466 DUAL_GAIN_COMP_SMOOTH_RANGE Cross ref.: –

Rounding range for knee-point compensation Relevant for: HLA


Unit: %

Default: 2.5

Minimum: 0.0

Maximum: 10.0

Data type: FLOAT




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5467 NEG_DUAL_GAIN_COMP_FLOW Cross ref.: –

Knee-point compensation neg. flow Relevant for: HLA


Unit: %

Default: 10.0

Minimum: 0.2

Maximum: 95.0

Data type: FLOAT


5468 NEG_DUAL_GAIN_COMP_VOLTAGE Cross ref.: –

Knee-point compensation neg. voltage Relevant for: HLA


Unit: %

Default: 10.0

Minimum: 0.2

Maximum: 95.0

Data type: FLOAT


To calculate the inverse characteristic, the knee-point in the positive quad-rant of the valve characteristic is defined in MD 5464 and MD 5465 and inthe negative quadrant with MD 5467 and MD 5468.

The positive and negative valve flows at the knee-point referred to rated flow(MD 5107) are entered in 5464 and MD 5467 respectively.

The positive and negative valve voltages at the knee-point referred to ratedvalve voltage (MD 5109) are entered in MD 5465 and MD 5468 respectively.

When the same values (defaults) are set in MD 5464 and MD 5465, thecharacteristic is linear (without breakpoint in the zero range (default andwithout saturation (default)).

These breakpoint data are preset from the valve data (MD 5110, MD 5111)during the “Calculate controller data” operation. The presettings can be al-tered later. The rounding range is not a valve data and is therefore only pre-set to a default value. It can however be changed later by the user (MD5466). If necessary, a measurement can be taken to obtain a precise set-ting.

Note

A constant machining velocity of the drive directly at the knee-point of the valveis not recommended.

Valve characteristic with breakpoint at beginning of a saturation region

5485 POS_DUAL_GAIN_COMP_S_FLOW Cross ref.: –

Knee-point compensation pos. flow saturation Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 0.2

Maximum: 100.0

Data type: FLOAT


5486 POS_DUAL_GAIN_COMP_S_VOLT Cross ref.: –

Knee-point compensation pos. voltage saturation Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 0.2

Maximum: 100.0

Data type: FLOAT




04.0004.00

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5487 NEG_DUAL_GAIN_COMP_S_FLOW Cross ref.: –

Knee-point compensation neg. flow saturation Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 0.2

Maximum: 100.0

Data type: FLOAT


5488 NEG_DUAL_GAIN_COMP_S_VOLT Cross ref.: –

Knee-point compensation neg. voltage saturation Relevant for: HLA


Unit: %

Default: 100.0

Minimum: 0.2

Maximum: 100.0

Data type: FLOAT


To calculate the inverse characteristic, the beginning of a saturation range withparabolic rounding in the positive quadrant of the valve characteristic is definedin MD 5485 and MD 5486 and in the negative quadrant with MD 5487 and MD5488.

The positive and negative valve flows at the beginning of the saturation regionreferred to rated flow (MD 5107) are entered in MD 5485 and MD 5487 respec-tively.

The positive and negative valve voltages referred to valve rated voltage (MD5109) are entered in MD 5486 and MD 5488 respectively.

The saturation region is compensated by a root characteristic such that the in-tersection point lies on a continuous tangent and the characteristic ends at thepoint (100%, 100%).

With default 100% set in MD 5485 and MD 5486 or in MD 5487 and MD 5488, there is no saturation region in the positive or negative quadrant.

For more detailed explanation, see also Section 2.3.1 and Appendix A.

5470 OFFSET_COMPENSATION Cross ref.: –

Offset compensation Relevant for: HLA


Unit: –

Default: 0

Minimum: –4000

Maximum: 4000

Data type: WORD


Since the valves are operated under analog control, an offset voltage of the D/Aconverter or valve amplifier may cause a zero point error and thus a positiondeviation (if no I-action component has been activated). By adding a compensa-tion value, the offset error can be largely eliminated.

An automatic offset adjustment can be initiated with MD 5650 (see Section3.9.2).

Note

When closed-loop force control is active (MD 5241), offset compensation isabsolutely necessary because the I component of the velocity controller is de-activated with closed-loop force control.

Offset



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4.5.2 Control output filter

5280 NUM_OUTPUT_FILTERS [n] 0...7 index of the parameter set Cross ref.: –

Number of control output filters Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


The number of control output filters must be set in this machine data.

Table 4-6 Selecting the number of control output filters

0 No filter(s) active (default)

1 Filter(s) activated

Note


5281 OUTPUT_FILTER_TYPE [n] 0...7 index of the parameter set Cross ref.: –

Type of control output filter Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


The type of control output filter is entered in this machine data.

Table 4-7 Type of control output filter

Bit 00 Low pass (see MD 5284/5285)

Bit 01 Band-stop (see MD 5288/5289/5290)

5284 OUTPUT_FIL_1_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Natural frequency of control output filter 1 Relevant for: HLA


Unit: Hz

Default: 1000.0

Minimum: 10.0

Maximum: 8000.0

Data type: FLOAT



Input of natural frequency for control output filter 1 (PT2 low-pass). Setting avalue of <10 Hz for the natural frequency of the low pass initializes the filter as aproportional element with a gain of 1, irrespective of the associated damping.



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5285 OUTPUT_FIL_1_DAMP [n] 0...7 index of the parameter set Cross ref.: –

Damping of control output filter 1 Relevant for: HLA


Unit: –

Default: 1.0

Minimum: 0.05

Maximum: 1.0

Data type: FLOAT


Input of damping for control output filter 1 (PT2 low-pass).

5288 OUTPUT_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –

Blocking frequency of control output filter 1 Relevant for: HLA


Unit: Hz

Default: 3500.0

Minimum: 1.0

Maximum: 7999.0

Data type: FLOAT


Input of blocking frequency for control output filter 1 (bandstop)

5289 OUTPUT_FIL_1_BW [n] 0...7 index of the parameter set Cross ref.: –

Bandwidth of control output filter 1 Relevant for: HLA


Unit: Hz

Default: 500.0

Minimum: 5.0

Maximum: 7999.0

Data type: FLOAT


Input of –3dB bandwidth for control output filter 1 (bandstop).

5290 OUTPUT_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –

Numerator bandwidth for control output filter 1 Relevant for: HLA


Unit: Hz

Default: 0.0

Minimum: 0.0

Maximum: 7999.0

Data type: FLOAT


Input of numerator bandwidth for control output filter 1 (damped bandstop).

Setting a value of 0 initializes the filter as an undamped band-stop. The valueset in MD 5290 must not exceed twice the value set in MD 5289.



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4.5.3 Manipulated voltage limitation

5475 OUTPUT_VOLTAGE_LIMIT Cross ref.: –

Manipulated voltage limitation Relevant for: HLA


Unit: V

Default: 10.0

Minimum: 1.0

Maximum: 10.0

Data type: FLOAT


The manipulated variable setpoint is limited in the positive and negative direc-tions to the value set in MD 5475 before the D/A conversion. An identical valueis set for both limits. A ZK3 message (can be interrogated via PLC) is activatedwhen the limitation is violated.

5476 OUTPUT_VOLTAGE_INVERSION Cross ref.: –

Manipulated variable inversionBit 0= 0: No inversion

1: Inversion

Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


The voltage output (manipulated variable) can be inverted in machine data MD5476 in order to compensate for differences in sign in the piping or wiring. Alter-natively, the wiring of the manipulated variable for the valve could be altered.

Definition of direction: See Section 3.9.1.

Manipulatedvariable inversion



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4.6 Supply unit data

The supply unit is defined by

the modulus of elasticity of the hydraulic fluid,

the system pressure and

on pilot-actuated valves by the pilot pressure

at the cylinder working temperature.

These data influence the limit data (maximum velocity, maximum force...) aswell as the dynamic response characteristics of the drive system (corner fre-quencies).

5100 FLUID_ELASTIC_MODULUS Cross ref.: –

Fluid elastic module hydraulic oil Relevant for: HLA


Unit: bar

Default: 11000

Minimum: 1000

Maximum: 21000

Data type: FLOAT


5101 WORKING_PRESSURE Cross ref.: –

System pressure Relevant for: HLA


Unit: bar

Default: 0.0

Minimum: 0.0

Maximum: 350.0

Data type: FLOAT

Effective: Power On

5102 PILOT_OPERATION_PRESSURE Cross ref.: –

Pilot pressure Relevant for: HLA


Unit: bar

Default: 0.0

Minimum: 0.0

Maximum: 250.0

Data type: FLOAT


Note

The variable of the elasticity of oil as a function of temperature can be ignoredwith respect to industrial hydraulics.

MD 5100 defines the compressibility of the hydraulic fluid.

MD 5101 defines the pressure supplied by the hydraulic power unit.

MD 5102 defines the pressure for a pilot-actuated valve. Zero must be enteredvalves without pilot actuation.


4.6 Supply unit data

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4.7 Valve

The rated valve data define the key valve data at the rated operating point. Thelatter is defined by the

rated flow,

rated pressure drop and

rated voltage.

5106 VALVE_CODE Cross ref.: –

Valve code number Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 2000

Data type: UNS.WORD


5107 VALVE_NOMINAL_FLOW Cross ref.: –

Rate valve flow Relevant for: HLA


Unit: l/min

Default: 0.0

Minimum: 0.0

Maximum: 1000

Data type: FLOAT


5108 VALVE_NOMINAL_PRESSURE Cross ref.: –

Rated valve pressure drop (per control edge) Relevant for: HLA


Unit: bar

Default: 35.0

Minimum: 1.0

Maximum: 200.0

Data type: FLOAT


5109 VALVE_NOMINAL_VOLTAGE Cross ref.: –

Rated valve voltage Relevant for: HLA


Unit: V

Default: 10.0

Minimum: 0.5

Maximum: 15.0

Data type: FLOAT


Valves with the associated data are included in the valve selection list (see Sec-tion 2.3.2).

Other valve data are as follows:

Knee characteristic,

Flow ratio,

Dynamic definition with natural frequency and damping and

Valve configuration.

For a more detailed explanation of valves, see Section 2.3 and Appendix A.

5110 VALVE_DUAL_GAIN_FLOW Cross ref.: –

Valve knee-point flow rate Relevant for: HLA


Unit: %

Default: 10.0

Minimum: 0.2

Maximum: 95.0

Data type: FLOAT


5111 VALVE_DUAL_GAIN_VOLTAGE Cross ref.: –

Valve knee-point voltage Relevant for: HLA


Unit: %

Default: 10.0

Minimum: 0.2

Maximum: 95.0

Data type: FLOAT


Valve data


4.7 Valve

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A valve characteristic as shown in Fig. 2-10 results in an entry of 10 % in MD 5110 and 40 % in MD 5111. Entering the same value in both machine dataproduces a linear characteristic (default setting).

5112 VALVE_FLOW_FACTOR_A_B Cross ref.: –

Valve flow ratio betw. A and B ends Relevant for: HLA


Unit: –

Default: 1.0

Minimum: 0.5

Maximum: 2.0

Data type: FLOAT


The flow ratio specifies the ratio between the rated flow towards the A end andthe rated flow towards the B end.

5114 VALVE_NATURAL_FREQUENCY Cross ref.: –

Valve natural frequency Relevant for: HLA


Unit: Hz

Default: 150.0

Minimum: 1.0

Maximum: 1000.0

Data type: FLOAT


5115 VALVE_DAMPING Cross ref.: –

Valve damping Relevant for: HLA


Unit: –

Default: 0.8

Minimum: 0.4

Maximum: 1.0

Data type: FLOAT


To dimension the velocity controller, the transmission behavior of the valve onconversion of the voltage setpoint to spool position is approximated as a PT2low-pass.

The valve natural frequency can be read off at a phase shift of –180°. The natu-ral valve frequency with a valve modulation of 10 % in relation to 100 bar pilotpressure is stated in MD 5114.

The valve damping can be calculated from the amplitude overshoot at resonantfrequency for values of less than 0.7. The valve damping for a valve modulationof 20 % in relation to 100 bar pilot pressure is stated in MD 5115.

To allow special valve features to be taken into account, machine data MD 5113with control bits has been introduced.

5113 VALVE_CONFIGURATION Cross ref.:–

Valve configurationBit 0= 0: Directly actuated valve

1: Pilot-actuated valveBit 2/Bit 1= 00: No fail-safe

01: Fail safe closed10: Fail-safe open11: –

Bit 3= 0: No differential circuit 1: Differential circuit

Bit4= 0: 7-pin connector1: 12-pin connector

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: 1F

Data type: UNS.WORD


Special features


4.7 Valve

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4.8 Cylinder drive

5131 CYLINDER_PISTON_DIAMETER Cross ref.: –

Cylinder piston diameter Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 500.0

Data type: FLOAT

Effective: Power On

5132 CYLINDER_ROD_A_DIAMETER Cross ref.: –

Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 500.0

Data type: FLOAT

Effective: Power On

5133 CYLINDER_ROD_B_DIAMETER Cross ref.: –

Cylinder piston rod diameter at B end Relevant for: HLA

Protection level:

Immediately

Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 500.0

Data type: FLOAT

Effective: Power On

5134 PISTON_STROKE Cross ref.: –

Piston stroke Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 3000.0

Data type: FLOAT


5135 CYLINDER_DEAD_VOLUME_A Cross ref.: –

Cylinder dead volume at A end Relevant for: HLA


Unit: ccm

Default: 0.0

Minimum: 0.0

Maximum: 200000.0

Data type: FLOAT


5136 CYLINDER_DEAD_VOLUME_B Cross ref.: –

Cylinder dead volume at B end Relevant for: HLA


Unit: ccm

Default: 0.0

Minimum: 0.0

Maximum: 200000.0

Data type: FLOAT


Apart from the piston diameter (MD 5131), the rod diameters at the A and Bends must also be specified (5132, MD 5133). On a differential cylinder, bothrod diameters are different, one of the rods might even have a zero diameter.The maximum piston stroke (MD 5135) and cylinder dead volume (MD 5135,MD 5136) are also required.

The cylinder dead volume is the liquid volume between the cylinder and servo solenoid valve which cannot be displaced by the piston.

The dead volume attributable to the pipework is separately parameterized (MD5141 to MD 5143).

For a more detailed explanation of the cylinder data, see also Section 2.3.1 andAppendix A.

Cylinder data


4.8 Cylinder drive

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4.9 Drive data

5140 VALVE_CYLINDER_CONNECTION Cross ref.: –

Valve-cylinder connection configurationBit 0 = 0: Valve A on cylinder A

1: Valve A on cylinder B

Relevant for: HLA


Unit:–

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


5141 PIPE_LENGTH_A Cross ref.: –

Pipe length at A end Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 10000.0

Data type: FLOAT


5142 PIPE_LENGTH_B Cross ref.: –

Pipe length at B end Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 10000.0

Data type: FLOAT


5143 PIPE_INNER_ DIAMETER_A_B Cross ref.: –

Internal pipe diameters at A and B Relevant for: HLA


Unit: mm

Default: 5.0

Minimum: 0.0

Maximum: 100.0

Data type: FLOAT


These machine data provide information about the valve-to-drive connection.They are used to preset other machine data during the “Calculate drive modeldata” and “Calculate controller data” routines. If there is a pipe between thevalve and cylinder, then the dead volume of the pipe can be calculated from thepipe length (A and B ends) and the inner pipe diameter. If the valve is mounteddirectly on the cylinder, then zero must be entered for the pipe length at eachend. The dead volume affects the natural frequency of the drive.

For more detailed explanation of the drive data, see also Section 2.3.4 and Ap-pendix A.

5150 DRIVE_MASS Cross ref.: –

Moved drive mass Relevant for: HLA


Unit: kg

Default: 0.0

Minimum: 0.0

Maximum: 20000.0

Data type: FLOAT


The movement of the piston rod is transmitted to other mechanical components(e.g. table, tools, ...). The total moved mass must be specified as a machinedata (MD 5150).

Valve-to-driveconnection

Mechanical drivecomponents


4.9 Drive data

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Note

The mass of the drive is a critical parameter and should be calculated as ex-actly as possible!

5151 CYLINDER_A_ORIENTATION Cross ref.: –

Cylinder mounting position referred to A end Relevant for: HLA


Unit: Degrees

Default: 0.0

Minimum: –90.0

Maximum: 90.0

Data type: FLOAT


5152 CYLINDER_FASTENING Cross ref.: –

Stationary part of HLABit 0= 0: Cylinder

1: Piston rod

Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 1

Data type: UNS.WORD


The mounting position of the cylinder (MD 5151) specifies to what degree theforce due to weight of the moved mass (MD 5150) is taken into account in cal-culating the servo gain and maximum piston travel-in/travel-out speed.

It is assumed that the moved mass will act in the direction of the cylinder axis. Ifthe weight of the moved mass does not act in this direction, however, MD 5151must be converted accordingly.

A distinction is made between two different mounting methods in the HLA:

1. The cylinder is stationary, the moved mass is attached to the piston rod (MD5152 bit 0=0).

2. The piston is stationary, the moved mass is attached to the cylinder (MD5152 bit 0=1).

The “Calculate drive model data” routine calculates the weight force applied tothe cylinder from MD 5150...MD 5152 and enters the result in MD 5231.

A

B

MD 5150

Positive sign inMD 5151

A

B

MD 5150

Negative sign inMD 5151

Fig. 4-15 Mounting position of drive referred to A end


4.9 Drive data

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5160 PISTON_POS_MIN_NAT_FREQ Cross ref.: –

Min. natural frequency, piston position Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: 0.0

Maximum: 3000.0

Data type: FLOAT


5161 DRIVE_DAMPING Cross ref.: –

Drive damping Relevant for: HLA


Unit: –

Default: 0.1

Minimum: 0.01

Maximum: 1.0

Data type: FLOAT


5162 DRIVE_NATURAL_FREQUENCY_A Cross ref.: –

Natural frequency of drive A Relevant for: HLA


Unit: Hz

Default: 1.0

Minimum: 1.0

Maximum: 2000.0

Data type: FLOAT


5163 DRIVE_NATURAL_FREQUENCY Cross ref.: –

Natural frequency of drive Relevant for: HLA


Unit: Hz

Default: 1.0

Minimum: 1.0

Maximum: 2000.0

Data type: FLOAT


5164 DRIVE_NATURAL_FREQUENCY_B Cross ref.: –

Natural frequency of drive B Relevant for: HLA


Unit: Hz

Default: 1.0

Minimum: 1.0

Maximum: 2000.0

Data type: FLOAT


5180 CLOSED_LOOP_SYSTEM_DAMPING Cross ref.: –

Selected damping for closed-loop system Relevant for: HLA


Unit: –

Default: 0.7

Minimum: 0.2

Maximum: 1.0

Data type: FLOAT


The drive is approximated as a PT2 low pass for the purpose of dimensioningthe closed-loop velocity control. The characteristic values “natural frequency”and “damping” are calculated and preset from other drive data by the “Calculatedrive model data” function.

Machine data MD 5180: CLOSED_LOOP_SYSTEM_DAMPING can be set tospecify the degree of damping to be applied in calculating the control loop dur-ing “Calculate controller data”.

Example: Damping of 0.9Slow closed-loop system with infrequent overshoots

Damping of 0.5Fast closed-loop system with frequent overshoots

Dynamic drivemodel data


4.9 Drive data

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4.10 Position measuring system

Only one measuring system can be connected for each axis to measure theposition of the piston rod. The A and B tracks of the measuring system mustproduce sinusoidal signals offset by 90° and an amplitude of 1 Vpp. The scalegraduations of a linear scale are subdivided 2048 times in the HLA module, thelower bits losing their significance in some cases. The sign of the actual-valuesensor can be reversed. (Signs are reversed by a software function).

The minimum or maximum possible velocity is dependent upon the positionmeasuring system.

Vmax: of the position measuring system must not be exceeded.

The maximum measuring velocity must be set in MD 5609:ENC_SPEED_LIMIT (see Section 4.13.1).

Vmax must not exceed the 350 kHz bar frequency of the connected measur-ing system.

Vmax,bar=scale graduation 350000 s–1

Vmin: The number of crossed graduations per velocity controller cycle issmall at low velocities. In extreme cases, this can result in uneven move-ments at low velocities, large scale graduation and short velocity controllercycle.

Improve by: Select another position measuring system with smaller scale graduations or increase the velocity controller cycle.

A phase error on tracks A and B can be corrected with the phase error com-pensation function.

5008 ENC_PHASE_ERROR_CORRECTION Cross ref.: –

Encoder phase error compensation Relevant for: HLA


Unit: Degrees

Default: 0.0

Minimum: –20.0

Maximum: 20.0

Data type: FLOAT


5011 ACTUAL_VALUE_CONFIG Cross ref.: –

Actual-value sensing configurationBit 0= 0: No inversion

1: Inversion of actual valueBit1= 0: No phase error compens. activated

1: Phase error compensation activatedBit3= 0: No absolute value encoder (EnDat)

1: Absolute value encoder (EnDat) connectedBit4= 0: No linear measuring system

1: Linear measuring system connectedBit7= 0: No distance-coded measuring system

1: Distance-coded measuring system connectedBit8= 0: No zero marker selection by NC

1: Zero marker selection by NC

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: 65535

Data type: UNS.WORD

Effective: Power On

Description

Minimum and maximum velocity

Phase errorcompensation



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5024 DIVISION_LIN_SCALE Cross ref.: –

Linear scale graduations Relevant for: HLA


Unit: nm

Default: 20000

Minimum: 1000 (0)

Maximum: 5000000

Data type: UNS.WORD

Effective: Power On

The standard parameterizing machine data provided support only linear mea-suring systems. ROD encoders must be converted by the user, i.e. the distancetraversed by the drive between two (coarse) increments must be entered. Value0 is automatically entered if MD 5011 bit 4 is set to 0 (no linear measuring sys-tem). Rotary absolute encoders cannot be implemented until sofware versionHLA 01.01.11 and beyond

5021 ENC_ABS_TURNS_MOTOR Cross ref.: –

Multi-turn resolution of absolute encoder on motor Relevant for: HLA


Unit: Rev

Default: 4096

Minimum: 0000

Maximum: 65535

Data type: WORD

Effective: Power On

Number of displayable revolutions of absolute encoder in motor measuring sys-tem. The value is read-only.

5022 ENC_ABS_RESOL_MOTOR Cross ref.: –

Measuring steps of absolute track in motor Relevant for: HLA


Unit: –

Default: 8192

Minimum: 0000

Maximum: 65535

Data type: WORD

Effective: Power On

Resolution of motor absolute encoder in measuring pulses per revolution. Thevalue is read-only.

5023 ENC_ABS_DIAGNOSIS_MOTOR Cross ref.: –

Diagnosis bits of absolute encoder, measuring systemBit 0=1: “Lighting failure”Bit 1=1: “Signal amplitude too low”Bit 2=1: “Faulty code connection”Bit 3=1: “Overvoltage”Bit 4=1: “Undervoltage”Bit 5=1: “Overcurrent”Bit 6=1: “Battery must be replaced”Bit 7=1: “Checksum error”Bit 8=1: “EnDat encoder cannot be used”Bit 9=1: Reserved

Bit 10=1: “Protocol cannot be interrupted”Bit 11=1: “SSI level in data line detected”Bit 12=1: “TIMEOUT on measured value reading”Bit 13=1: “CRC error”Bit 14=1: UnassignedBit 15=1: “Encoder defective”

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: BFFF

Data type: UNS.WORD


Diagnostic bits of absolute encoder, motor measuring system

Scale graduationsof linear scale



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5040 PISTON_ZERO Cross ref.: –

Piston zero in relation to machine zero Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: –1000000.0

Maximum: 100000.0

Data type: FLOAT


The offset between the piston zero (end stop at A end) and machine zero mustbe set in MD 5040: PISTON_ZERO.

If the actual position is available in machine coordinates in the drive after thereference point approach, it can be applied to calculate the piston position (e.g.for adaptation).

Actual position



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4.11 Pressure sensors

5550 PRESSURE_SENS_A_REF Cross ref.: –

Reference value of pressure sensor A at 10 V Relevant for: HLA


Unit: bar

Default: 200.0

Minimum: 50.0

Maximum: 400.0

Data type: FLOAT


5552 PRESSURE_SENS_B_REF Cross ref.: –

Reference value of pressure sensor B at 10 V Relevant for: HLA


Unit: bar

Default: 200.0

Minimum: 50.0

Maximum: 400.0

Data type: FLOAT


The pressure at which the pressure sensor at the A and B cylinder ends outputs10 V is entered in bar in MD 5550: PRESSURE_SENS_A_REF and MD 5552: PRESSURE_SENS_B_REF.

The pressure sensor should have a range of 0 to 10 V, with 0 bar pressure rep-resented by 0 V and the reference value (MD 5550 or. MD 5552) by 10 V.

5551 PRESSURE_SENS_A_OFFS Cross ref.: –

Offset adjustment for pressure sensor A Relevant for: HLA


Unit: –

Default: 0

Minimum: –32760

Maximum: 32760

Data type: WORD


5553 PRESSURE_SENS_B_OFFS Cross ref.: –

Offset adjustment for pressure sensor B Relevant for: HLA


Unit: –

Default: 0

Minimum: –32760

Maximum: 32760

Data type: WORD


The offset of the pressure sensor at the cylinder A and B ends is adjusted inADC increments in MD 5551: PRESSURE_SENS_A_OFFS and MD 5553: PRESSURE_SENS_B_OFFS.

The pressure indicator should also display 0 bar at zero pressure. If the velocity controller cycle is altered, the offset must be adjusted again.

Note

For automatic offset adjustment, see Section 3.9.2.

Sensor adjustment

Offset adjustment


4.11 Pressure sensors

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4.12 Terminals

Terminals are provided on connectors X431/X432 of the HLA module and X121of the NE module for the purpose of implemented the ON/OFF conditions for theHLA module.

The following overview shows the hierarchy of signals for enabling and disab-ling the HLA.

Controller enableterm. 64

Controller enable error

Controller enable NC &

Velocity setpointbraking ramp

Control wordcontroller enable

Timerpower disable

Preset

Timerpower enab-ling period

Preset

&

OR

&Power enableterm. 663

External 26.5 Vavailable

Power enableterm. 63

Power disableerror

Power enableNC

Timer manip-ulated vari-able time ON

Preset Timerrundown &

&StatuscontrollerenableStatuspower en-able

Timerrundown

MD 5530Bit 3=1

Timerrundown

Control wordpower enable

Timermanipulatedvariable timeOFF

Preset

&

Timerrundown

OR&MD 5530

Bit 4=1MD 5530Bit 0=1

SET

CLEAR

CLEAR

SET

24 V for shutoffvalve ON

24 V servo so-lenoid valveON

Fig. 4-16 Enabling logic on HLA module

The 24 V voltage for the shutoff valve and valve electronics is supplied from anexternal source connected via the HLA module.

ON/OFF sequence

External 26.5 Vsupply


4.12 Terminals

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This voltage source is monitored by the HLA module such that an internal sig-nalling bit “24 V valve supply voltage missing” is set by the hardware when thevoltage drops below a specific threshold. As long as the “valve supply voltagemissing” bit is set, a power enable command is rejected and thus the status bit“Velocity controller enable” also set to zero.

Failure of 26.5 V supply during operation

The power is disabled and status bit “Velocity controller enable” canceled. The module does not output an error message.

Recovery of 26.5 V supply voltage or after initial connection of the26.5 V supply voltage

The power is not enabled until the power enabling delay set in MD 5532 hasexpired.

!Warning

In the event of sudden failure (e.g. open circuit) of the external 26.5 V supply,an axial storage capacitor on the HLA module provides energy to supply theservo solenoid valve until such time as the pressure supply for a configuredshutoff valve is disabled.

The machine manufacturer must verify the interaction between valves, makingallowance for all tolerances in the controlled system.

The energy content of the storage capacitors is dependent upon

the tolerances of the capacitors,

The available reaction time is mainly defined by

the power required for the current machining step,

the response time of the shutoff valves and

the trip threshold of the servo solenoid valves.

5532 POWER_ENABLE_DELAY Cross ref.: –

Power enable delay period Relevant for: HLA

Protection level:

Unit: ms

Default: 100

Minimum: 0

Maximum: 300

Data type: UNS.WORD


If a shutoff valve is connected (MD 5530, bit 0=1), the switch remains openfor that time, i.e. the shutoff valve is closed.

This gives the servo solenoid valve time to move into the mid-position with-out pressure from the fail-safe position. In such cases, the power enablingdelay period must be set to the time required by the valve to move from fail-safe to mid-position.

If this operation were to take place under pressure, the drive would move. Ifno shutoff valve is connected, zero can be entered as the power enablingdelay period.


4.12 Terminals

04.00

02.99



Figs. 4-17 and 4-18 show the system response to 24 V ON and OFF for a con-figuration with and without shutoff valve.

Chronological sequence after connection of 24 V with shutoff valvePower enable and velocity controller commands issued, setpoint > 0

24 V missingmessage

Status bitPower enable

Switch forShutoff valve

Power enable delay time

Manipulated variable enable delayStatus bitVelocitycontroller enable

closedopen

Effectivevelocitysetpoint

24 V supply

Shutoff valve openclosed

Valve spoolposition Zero

Fail-safeBack-up capacitor prolongs 24 Vsupply for valve electronics

Switch forservo solenoidvalve supply

closed

openThe valve supply is disconnected onlyif bit 4 in MD 5530 is set to zero

Fig. 4-17 Chronological sequence after connection of 24 V supply, with shutoff valve

Chronological sequence after connection of 24 V without shutoff valvePower enable and velocity controller enable commands issued, setpoint > 0

24 V missingmessage

Status bitPower enable

Switch forShutoff valve

Power enable delay period MD 5532

Manipulated variable delay time MD 5531

closedopen

Effectivevelocitysetpoint

24 V supply

Shutoff valve openclosed

Valve spoolposition Zero

Fail-safe

Switch for servosolenoid valve supply

closedopen

No shutoff valve connected

Status bitVelocitycontroller enable

Fig. 4-18 Chronological sequence after connection of 24 V supply, without shutoff valve


4.12 Terminals

02.99


The power enabling command (corresponding to pulse enable on an electricaldrive) can be issued and/or cancelled via the following paths:

Term. 63 (central power enable)

Term. 663 (module-specific power enable)

Control word (from NC)

Error (ZK1, watchdog)

5530 CYLINDER_SAFETY_CONFIG Cross ref.: –

Safety configuration

Bit 0= 0: Without shutoff valve1: With shutoff valve

Bit 1= 0: Central shutoff valve1: Axis-specific shutoff valve

Bit 2= 0: No valve spool checkback1: Valve spool checkback available

Bit 3= 0: Velocity controller disable with power disable (PD) 1: Velocity controller disable without power disable (PD)

Bit 4= 0: Servo solenoid valve supply switched off at PD with switchoff valve (no meaning without switchoff valve)

1: Servo solenoid valve remains switched on at PD with switchoff valve (no meaning without switchoff valve)

(PD Power disable)

Relevant for: HLA


Unit: HEX

Default: 4

Minimum: 0

Maximum: 31

Data type: UNS.WORD


5531 OUTPUT_ENABLE_DELAY Cross ref.: –

Manipulated variable enable delay Relevant for: HLA


Unit: ms

Default: 300

Minimum: 0

Maximum: 500

Data type: UNS.WORD


The manipulated variable delay time is the time which the velocity controllerenable continues to disable after the power enable delay time (MD 5532) hasexpired. This delay time is needed to allow the shutoff valve to open or, in sys-tems without shutoff valve, to allow the valve spool to change from fail-safe tozero position.

Switching of the shutoff vavle supplyIf a shutoff valve is parameterized in MD 5530 (bit 0 or bit 1 = 1) and the supplyvoltage of the servo solenoid valve is to be switched off when the power is dis-abled (MD 5530 bit=0), the manipulated variable delay time (MD 5531) is thetime it takes until the voltage supply of the servo solenoid valve is interrupted.The shutoff valve can be closed during this period.

Operating sequence for PE (power enable) (ext. 24 V supply available, con-trollers enabled):

24 V supply for servo solenoid valve is switched on immediately (if it is notalready connected).

If 24 V supply for servo solenoid valve was available, then 24 V supply forshutoff valve is switched on immediately, otherwise it is not switched on untilpower enable delay period has run down.

After the 24 V supply for the shutoff valve has been switched on, the statusword “Velocity controller enable” is not set until the manipulated variableenable delay has run down.

Power enable


4.12 Terminals

04.00

02.99



Operating sequence for PD (power disable):

24 V supply for shutoff valve is disconnected immediately (shutoff valvecloses).

If MD 5530 bit 4=0 is set, the 24 V supply for the servo solenoid valve is alsoswitched off when the manipulated variable enable delay (MD 5531) runsdown (servo solenoid valve moves to fail-safe position).

If MD 5530 bit 4=1 is set, the 24 V supply for the servo solenoid valve re-mains connected.

If MD 5530 bit 0=0 is set (no shutoff valve), then the 24 V supply for theservo solenoid valve is switched off immediately (servo solenoid valvemoves to fail-safe position).

“Velocity controller enable” status bit is reset immediately.

– Valve setpoint=0 V is output

– I-action components of controllers are cancelled.

– Valve spool monitoring is deactivated

If a central shutoff valve is installed, it is the user’s responsibility to gatethe signals (e.g. using the PLC) in such a way that the central shutoff valveis actuated when the power is disabled.

To prevent errors on other axes, it should be ensured that all axes whosepressure is supplied via the central shutoff valve also receive the “powerdisable” command when the central shutoff valve is actuated.

If a separate shutoff valve (axis-specific shutoff valve) is installed for eachaxis, this need only be connected to the “shutoff valve” relay output of therelevant axis.

After the power has been disabled, the switch for the 24 V supply is eitheropened or not (depending on the setting of bit 4 in MD 5530) at the end of themanipulated variable enable delay. The default setting has been selected suchthat the 24 V valve supply voltage is disconnected (bit 4 =0) so as to bring thevalve into the fail-safe position.

This will not be necessary if a shutoff valve is installed and actuated. This func-tion has been integrated for cases where a shutoff valve is parameterized, butnot actually connected. In such cases, this function prevents the drive from be-ing able to drift after a power disable. After a function test, bit 4 in MD 5530 canbe set to 1.

A velocity controller enable/disable can be requested via the following paths:

Terminal 64 (central velocity controller enable)

Control word (from NC)

Error (ZK1)

If a velocity controller enable is requested and all the relevant enable conditionsare fulfilled, i.e.

manipulated variable enable delay run down,

24 V supply for shutoff and SS valves ON,

power enable signal set and

no errors,

then the “Velocity controller enable” status bit is set.

Velocity controllerenable


4.12 Terminals

02.99


Mode of operation when “Velocity controller enable” bit is set:

Valve setpoint is output by the velocity controller

I-action component is enabled

Valve spool monitor is activated

If a velocity controller disable is requested, a zero velocity setpoint is output.

The braking time set in MD 5402 acts as a speed setpoint adjustment ramp(acceleration limitation).

The setting in MD 5402 corresponds to the time required by the brakingramp to decelerate the cylinder from the speed in MD 5401 down to zero.This ramp is effective only when the velocity controller is disabled since, inthis case, the acceleration limits programmed in the control are ignored.Otherwise, the control system has the responsibility of limiting accelerationrates.

In cases where velocity controller disable followed by a power disable isrequested(MD 5530 bit 3=0), then the delay set in MD 5404:POWER_DISABLE_DELAY is left to run down after the velocity controllerdisable request until the power disable signal is set. When MD 5530, bit 3=1,MD 5404 has no meaning (drive continues to operate under closed-loopcontrol with a zero velocity setpoint after a velocity controller disable re-quest).

5402 SPEED_CTRL_DISABLE_STOPTIME Cross ref.: –

Braking time for controller disable Relevant for: HLA


Unit: ms

Default: 0.0

Minimum: 0.0

Maximum: 120000.0

Data type: FLOAT


5404 POWER_DISABLE_DELAY Cross ref.: –

Power disable timer Relevant for: HLA


Unit: ms

Default: 100

Minimum: 0

Maximum: 100000

Data type: FLOAT


If the setup mode terminal (term. 112 on NE module) is selected, the velocitysetpoint is limited to the value programmed in MD 5420.

5012 FUNC_SWITCH Cross ref.: –

Status word (PLC readable) Drive readyBit 2=0:Drive signaled as ready if not drive alarm is pendingBit 2=1:Drive signaled as ready if not drive alarm is pending

and terminals 63, 64, 48 and 663=1Bit 4=1:ZK2 parameterization error

Bit 14=1:Valid offset between machine zero and actual value zero

Bit 15=1:Valid offset between piston zero and machine zero

Relevant for: HLA


Unit: –

Default: 4

Minimum: 0

Maximum: 65535

Data type: UNS.WORD


Only bits 2 and 4 are relevant for the user.

This LED indicates the readiness to operate of the drive unit (Simodrive Readyterminal 72/73 –> device bus; cannot be changed by MD 5012).

Velocity controllerdisable

Setup mode

Function switch

SIMRDY


4.12 Terminals

04.00

02.99



4.13 Monitoring functions

4.13.1 Alarms

5600 ALARM_MASK_POWER_ON Cross ref.: –

Concealable alarms (Power On)Bit 4: “Measuring circuit measuring system”Bit 5: Measuring circuit absolute trackBit 8: “Zero marker error”

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


5612 ALARM_REACTION_POWER_ON Cross ref.: –

Config. shutdown reaction to PO alarmsBit 0= 0: No enable signal cancellation in response to

internal errors1: Enable signal cancellation in response to internal

errors

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


5731 CL1_PO_IMAGE Cross ref.: –

Image ZK1_PO register Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


MD 5600: ALARM_MASK_POWER_ON can be set to conceal Power Onalarms. If the relevant bit is set to 0, the corresponding error monitoring functionis active. If the bit=1, the error monitoring function is suppressed. The defaultsetting is “active” for all monitoring functions.MD 5612: ALARM_REACTION_POWER_ON is set to configure switchover ofthe relevant Power On alarm.For alarm messages, see Chapter 6, numbers 300500...300599.

5601 ALARM_MASK_RESET Cross ref.: –

Concealable alarms (Reset)Bit 7: “Valve controller not reacting”Bit 8: “Velocity controller at limit”Bit 9: “Encoder limit frequency exceeded”

Bit 10: “Piston position negative”Bit 11: “Pressure measurement failure”Bit 12: “Force limitation OFF”

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


5613 ALARM_REACTION_RESET Cross ref.: –

Config. shutdown reaction to RESET alarmsBit 0= 0: No enable signal cancellation in response to

configuration errors1: Enable signal cancellation in response to

configuration errors

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


Power On alarms

RESET alarms


4.13 Mounting functions

02.99


5732 CL1_RES_IMAGE Cross ref.: –

Image ZK1_RES register Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


MD 5601: ALARM_MASK_RESET can be set to conceal Reset alarms. If therelevant bit is set to 0, the corresponding error monitoring function is active. Ifthe bit=1, the relevant error message is suppressed. The default setting is “ac-tive” for all monitoring functions.

MD 5613: ALARM_REACTION_RESET is set to configure switchover of therelevant Reset alarm.

Alarm messages, see Chapter 6, numbers 300600...300699.

5609 ENC_SPEED_LIMIT Cross ref.: –

Max. measuring speed of linear scale Relevant for: HLA


Unit: mm/min

Default: 240 000.0

Minimum: 1.0

Maximum: 240 000.0

Data type: FLOAT


The limit frequency of the measured-value conditioning hardware is monitoredwith respect to A/B signals. The limit frequency is calculated from machine dataMD 5005 and MD 5609. It is approximately 100 kHz and is normally specifiedby the measuring system manufacturer.

Maximum measuring velocity (MD 5609) / increments (MD 5005) = encoder limitfrequency

Example: 120 000 mm/min / 20 µm = 100 kHz

5605 SPEEDCTRL_LIMIT_TIME Cross ref.: –

Time for velocity controller at limit Relevant for: HLA


Unit: ms

Default: 200.0

Minimum: 20.0

Maximum: 1000.0

Data type: FLOAT


5606 SPEEDCTRL_LIMIT_THRESHOLD Cross ref.: –

Threshold for velocity controller at limit Relevant for: HLA


Unit: mm/min

Default: 120 000.0

Minimum: 0.0

Maximum: 120 000.0

Data type: FLOAT


A message is activated if the manipulated voltage on the D/A converter is at thelimit continuously for a parameterizable time period and, at the same time, theactual velocity is lower than a parameterizable threshold (MD 5606).

Measuring circuitlimit frequencyreached

Velocity controllerat limit



02.99



5614 VALVE_ERROR_TIME Cross ref.: –

Valve spool monitoring timer Relevant for: HLA


Unit: ms

Default: 50

Minimum: 1

Maximum: 100

Data type: UNS.WORD


The valve spool position is returned on all Bosch valves. The message “Valvespool is not responding” is output if the valve spool position exits the tolerancefield of 10 % of maximum stroke around the setpoint for longer than the time setin MD 5614 when the power is enabled. This error message cannot be output ifno checkback signal is configured for the valve spool position (MD 5530).

4.13.2 Variable signalling functions

Input bit field for controlling the variable signalling function.

5620 PROG_SIGNAL_FLAGS Cross ref.: –

Bits of variable signalling functionBit 0= 0: Variable signalling function; not active

1: Variable signalling function; activeBit1= 0: Segment of variable signalling function; address

space X1: Segment of variable signalling function; address space Y

Bit 2=0: Compar. var. sign. fct.; compare without sign 1: Compar. var. sign. fct.; compare with sign

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: 7

Data type: UNS.WORD


Note

Bit 1 is effective only if signal number 0 is selected in MD 5621: PROG_SIG-NAL_NR.

A random memory location from address space X or Y in the data RAM is moni-tored for violation of a parameterizable threshold for the variable signalling func-tion. A tolerance band can be set around this threshold; this is taken into ac-count when the threshold is scanned for violation in either direction. Anyviolation of the tolerance band is signalled to the PLC. This violation messagecan be linked to a pickup and/or dropout delay. The signalling function operatesin a 4 ms cycle.

Valve spool is not responding



02.99


Threshold Tolerance band

Message to PLC

Dropout delay timePickup delay time

t

Fig. 4-19 Variable signalling function

Note

The quantity to be monitored can be selected through specification of either asignal number or a physical address, the physical address having relevanceonly for Siemens servicing activities.

The following machine data are related to MD 5620:

MD 5621: PROG_SIGNAL_NR

MD 5622: PROG_SIGNAL_ADDRESS

MD 5623: PROG_SIGNAL_THRESHOLD

MD 5624: PROG_SIGNAL_HYSTERESIS

MD 5625: PROG_SIGNAL_ON_DELAY

MD 5626: PROG_SIGNAL_OFF_DELAY

Note

Changed values which are entered in the machine data MD 5621 to MD 5624while the monitoring is already active ( MD 5620, Bit 0 = 1) do not automati-cally have the result that the PLC message is reinitialized, that means reset to0. If the message must be re-initialized, the monitoring function must beswitched off and on again via MD 5620, bit 0, after the MD setting has beenchanged.

5621 PROG_SIGNAL_NR Cross ref.: –

Signal number of variable signalling function Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 100

Data type: UNS. WORD


Input of signal number of memory location which must be monitored by the vari-able signalling function.



02.99



Table 4-8 Signal number of variable signalling function

Signal number Signal name Normalization(LSB corresponds to:)

0 No signal –

1 No signal –

2 Pressure p(A) (with pressure sensing) MD 57101)

3 Pressure p(B) (with pressure sensing) MD 57101)

4 Actual value spool value MD 57091)

5 Valve spool setpoint MD 57091)

6 Actual velocity value MD 57111)

7 Velocity setpoint (before filter, limitation) MD 57111)

8 Velocity setpoint (after filter, limitation) MD 57111)

9 Velocity setpoint reference model MD 57111)

10 Actual force (with pressure sensing) MD 57131)

11 Active power 1 inc 0.01 kW

12 Control deviation of velocity controller MD 57111)

13 Velocity controller P component MD 57091)

14 Velocity controller I component MD 57091)

15 Velocity controller D component MD 57091)

16 Velocity controller feedforward control component MD 57091)

17 Friction feedforward control component velocity controller MD 57091)

18 Velocity controller output (before filter) MD 57091)

19 Velocity controller output (after filter) MD 57091)

20 Actual position MD 57141)

21 Force setpoint MD 57131)

22 Force controller control deviation MD 57131)

23 Force controller P component MD 57091)

24 Force controller I component MD 57091)

25 Force controller D component MD 57091)

26 Feedforward control component force controller MD 57091)

27 Force controller output MD 57091)

28 Zero marker signal –

29 BERO signal –

1) see Section 4.14.3



02.99


5622 PROG_SIGNAL_ADDRESS Cross ref.:

Address to be monitored by variable signalling function Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


Input of address of memory location which must be monitored by the variablesignalling function.

Note

This machine data is effective only if the signal number is set to 0 (refer toMD 5621).

5623 PROG_SIGNAL_THRESHOLD Cross ref.: –

Threshold for variable signalling function Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


Input of threshold for the memory location address entered in MD 5622:PROG_SIGNAL_ADDRESS which is to be monitored by the variable signallingfunction. In combination with MD 5624: PROG_SIGNAL_HYSTERESIS thisdata defines the actual value to be checked by the monitoring function (see dia-gram under MD 5620, Fig. 4-19).

Note

Depending on how machine data MD 5620: PROG_SIGNAL_FLAGS is set, thenumeric setting in MD 5623 is interpreted as an unsigned value (bit 2 = 0) or asigned value (bit 2 = 1).

5624 PROG_SIGNAL_HYSTERESIS Cross ref.: –

Hysteresis for variable signalling function Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


Input of hysteresis (tolerance band) for the memory location address entered in MD 5622: PROG_SIGNAL_ADDRESS which is to be monitored by the variablesignalling function. In combination with MD 5623: PROG_SIGNAL_THRESH-OLD, this data defines the actual value to be checked by the monitoring function(see diagram under MD 5620, Fig. 4-19).

Note

Depending on how machine data MD 5620: PROG_SIGNAL_FLAGS is set, the numeric setting in MD 5623 is interpretedas an unsigned value (bit 2 = 0) or a signed value (bit 2 = 1).



02.99



5625 PROG_SIGNAL_ON_DELAY Cross ref.: –

Pickup delay for variable signalling function Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 10 000

Data type: UNS.WORD


Input of pickup delay for setting of message if the monitored quantity exceedsthe threshold setting (with hysteresis) (see diagram under MD 5620, Fig. 4-19).

Note

Changing the settings in MD 5625: PROG_SIGNAL_ON_DELAY and MD 5626: PROG_SIGNAL_OFF_DELAY affects a time watchdog that is al-ready running. The monitor is initialized with the new time settings.

5626 PROG_SIGNAL_OFF_DELAY Cross ref.: –

Dropout delay for variable signalling function Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: 10 000

Data type: UNS.WORD


Input of dropout delay for resetting of message if the monitored quantity dropsbelow the threshold setting (with hysteresis) (see diagram under MD 5620, Fig.4-19).

Note

Changing the settings in MD 5625: PROG_SIGNAL_ON_DELAY and MD 5626: PROG_SIGNAL_OFF_DELAY affects a time watchdog that is al-ready running. The monitor is initialized with the new time settings.



02.99


4.14 Service functionsFor explanations regarding the

Measuring functions– Measurement of valve control loop– Measurement of velocity control loop– Measurement of position control loop

function generator,

Circularity test

Servo trace

DAC configurationplease refer to Section 3.11, Start-Up Functions.

5650 DIAGNOSIS_CONTROL_FLAGS Cross ref.: –

Diagnostic controlBit 0: Min/Max memoryBit 1: Min/Max memory segmentBit 2: Signed comparisonBit 8: Interpretation of velocities as forces

measuring functions, function generatorBit 12: Offset adjustment P_a, P_bBit 13: Offset adjustment of valve spool setpoint

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


MD 5650 is important for diagnostic and start-up purposes.

For information about adjusting the pressure sensor and valve setpoint offsets,see Section 3.9.2.

To start up the force controller, it is possible to redirect the measuring functionsand function generator from the velocity controller to the forcecontroller by setting bit 8 (see Section 4.4).

4.14.1 Min/max display

Note

Machine data MD 5651 to MD 5654 are relevant only for internal Siemensfunctions and must not be changed.

5651 MINMAX_SIGNAL_NR Cross ref.: –

Signal number of min/max memory Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


5652 MINMAX_ADDRESS Cross ref.: –

Memory location in min/max memory Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD



4.14 Service functions

08.99

02.99



5653 MINMAX_MIN_VALUE Cross ref.: –

Maximum value of min/max memory Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


5654 MINMAX_MAX_VALUE Cross ref.: –

Maximum value of min/max memory Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


4.14.2 Monitor

Note

Machine data MD 5655 to MD 5659 are relevant only for internal Siemensfunctions and must not be changed.

5655 MONITOR_SEGMENT Cross ref.: –

Monitor memory location segment Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


5656 MONITOR_ADDRESS Cross ref.: –

Monitor memory location address Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


5657 MONITOR_DISPLAY Cross ref.: –

Monitor value display Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


5658 MONITOR_INPUT_VALUE Cross ref.: –

Monitor value input Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD


5659 MONITOR_INPUT_STROBE Cross ref.: –

Monitor value transfer Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD




02.99


4.14.3 Diagnostic machine data

A range of different machine data are provided in the HLA module for diagnosticfunctions. NC diagnostic displays are available in a similar way to those used onelectrical drives.

5700 TERMINAL_STATE Cross ref.: –

Status of binary inputs

Bit 0: 26.5 V supply availableBit 1: Term. 663 availableBit 2: Term. 63 availableBit 3: Group signal HW enable availableBit 5: Setup mode selectedBit 6: Term. 64 available

Bit 12: 24 V for servo solenoid valve ONBit 13: 24 V for shutoff valve ON

Relevant for: HLA


Unit: HEX

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


5704 ACTUAL_PRESSURE_A Cross ref.: –

Actual pressure A Relevant for: HLA


Unit: bar

Default: 0.0

Minimum: –10000.0

Maximum: 10000.0

Data type: FLOAT


5705 ACTUAL_PRESSURE_B Cross ref.: –

Actual pressure B Relevant for: HLA


Unit: bar

Default: 0.0

Minimum: –10000.0

Maximum: 10000.0

Data type: FLOAT


5706 DESIRED_SPEED Cross ref.: –

Velocity setpoint Relevant for: HLA


Unit: mm/min

Default: 0.0

Minimum: –240000.0

Maximum: 240000.0

Data type: FLOAT


5707 ACTUAL_SPEED Cross ref.: –

Actual velocity value Relevant for: HLA


Unit: mm/min

Default: 0.0

Minimum: –240000.0

Maximum: 240000.0

Data type: FLOAT


5709 VOLTAGE_LSB Cross ref.: –

Significance of voltage representationDefines how many volts [V] correspond to 1 incrementof the internal voltage format (valve spool setpoint/actual value).

Relevant for: HLA


Unit: V

Default: 0.0

Minimum: –100000.0

Maximum: 100000.0

Data type: FLOAT


5710 PRESSURE_LSB Cross ref.: –

Significance of pressure representationDefines the pressure in [bar] corresponding to 1 increment of the internal pressure format.

Relevant for: HLA


Unit: bar

Default: 0.0

Minimum: –240000.0

Maximum: 240000.0

Data type: FLOAT




02.99



5711 SPEED_LSB Cross ref.: –

Significance of velocity representationDefines the velocity in [mm/min] corresponding to 1 increment of the internal velocity format.

Relevant for: HLA


Unit: mm/min

Default: 0.0

Minimum: –240000.0

Maximum: 240000.0

Data type: FLOAT


5713 FORCE_LSB Cross ref.: –

Significance force displayIndicates the value to which one increment of the internal force corresponds in [µN].

Relevant for: HLA


Unit: µN

Default: 0.0

Minimum: –10000000.0

Maximum: 10000000.0

Data type: FLOAT


5714 POSITION_LSB Cross ref.: –

Significance of position representationDefine the position in [nm] corresponding to 1 increment of the internal position format.

Relevant for: HLA


Unit: nm

Default: 0.0

Minimum: –1000000.0

Maximum: 1000000.0

Data type: FLOAT


5715 DESIRED_VALVE_SPOOL_POS Cross ref.: –

Voltage for valve spool position setpoint Relevant for: HLA


Unit: V

Default: 0.0

Minimum: –10.0

Maximum: 10.0

Data type: FLOAT


5716 ACTUAL_VALVE_SPOOL_POS Cross ref.: –

Voltage for actual valve spool position Relevant for: HLA


Unit: V

Default: 0.0

Minimum: –10.0

Maximum: 10.0

Data type: FLOAT


5725 MAX_FORCE_FROM_NC Cross ref.: –

Normalization of force setpoint interfaceInterface high-speed PLC data channel.Value corresponding to 4000hex in MD 5725.

Relevant for: HLA


Unit: N

Default: 0.0

Minimum: 0.0

Maximum: 10000000.0

Data type: FLOAT


5740 ACTUAL_POSITION Cross ref.: –

Actual position with respect to machine zero Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: –10000000.0

Maximum: 10000000.0

Data type: FLOAT


5741 ACTUAL_PISTON_POSITION Cross ref.: –

Piston position with respect to piston zero Relevant for: HLA


Unit: mm

Default: 0.0

Minimum: –10000000.0

Maximum: 10000000.0

Data type: FLOAT




02.99


5730 OPERATING_MODE Cross ref.: –

Display of the operating modeBit 0=1: Velocity controller activeBit 1=1: Force limitation activeBit 2=1: Friction compensation activeBit 3=1: Velocity controller adaptation activeBit 4=1: Piston position knownBit 8=1: Force limitation ONBit 9=1: Friction compensation ON

Bit 10=1: Simple force limitation ON

Relevant for: HLA


Unit: HEX

Default: 1

Minimum: 1

Maximum: FFFF

Data type: UNS.WORD


5790 ENC_TYPE Cross ref.: –

Measuring circuit type of measuring system0: IPU (V) unconditioned voltage signals

1...15: Reserved16: EnDat encoder

Relevant for: HLA


Unit: –

Default: 0

Minimum: –1

Maximum: 32767

Data type: WORD


5720 CRC_DIAGNOSIS Cross ref.: –

CRC diagnostic parameter Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: FFFF



The purpose of machine data MD 5720 is to display any detected CRC errors(cyclic redundancy check). The counter information is displayed on every readrequest and is 5 bits wide (bit 4...bit 0 or count 0...31).

Note

The assignment of CRC errors to the respective drives is not assured in allcases. The “wrong” module (if installed) displays the error when the address isincorrect.

5708 ACTUAL_CYL_FORCE Cross ref.: –

Actual cylinder force Relevant for: HLA


Unit: N

Default: 0.0

Minimum: –10000000.0

Maximum: 10000000.0

Data type: FLOAT


The cylinder force is calculated from the actual pressures in A and B (providedthat pressure sensors are connected at X111/X112) and displayed in MD 5708.This value is irrelevant if no pressure sensor is connected.

5717 DESIRED_CYL_FORCE Cross ref.: –

Cylinder force setpoint Relevant for: HLA


Unit: N

Default: 0.0

Minimum: –10000000.0

Maximum: 10000000.0

Data type: FLOAT




08.99

02.99



If the force controller (force limitation or friction injection) has been activated inMD 5241, the effective force setpoint is displayed here. It can be set by theforce limitation function (MD 5230 or 5231) or friction injection function (MD5234 or MD 5235).

It must be noted that the force controller is activated only in conjunction withfriction injection and zero speed or with force limitation and violation of the upperforce limitation. The voltage setpoint of the velocity controller is otherwise ap-plied, in which case the force setpoint is irrelevant.

5797 PBL_VERSION Cross ref.: –

Data version Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


Output of current data version (machine data list).

5798 FIRMWARE_DATE Cross ref.: –

Firmware date Relevant for: HLA


Unit: –

Default: 0

Minimum: 0

Maximum: FFFF

Data type: UNS.WORD


Output of coded software release. The display is decimal. The character stringhas the following format: DDMMY, in which DD stands for day, MM for monthand Y = last digit of year.

Example: The code for 01.06.1993 is 1063dec

5799 FIRMWARE_VERSION Cross ref.: –

Firmware version Relevant for: HLA

Protection level:

Unit: –

Default: 0

Minimum: 0

Maximum: FFFFFF

Data type: UNS.WORD

Effective: Read Only

Output of current software release. The display is decimal, e.g. 21000. This isthe code for SW version 2.10/00.

5735 PROCESSOR_UTILIZATION Cross ref.: –

Processor capacity utilization Relevant for: HLA


Unit: %

Default: 0

Minimum: 0

Maximum: FFFF


Effective: Read only

The processor capacity utilization display provides online information aboutavailable computing capacity.

Software version

Processor capacityutilization



02.99


4.15 Table of parameters

The machine data is preset to this value during start-up.

Specifies the input limits. If no value range is indicated, the data byte deter-mines the input limits and the field is marked with “∗∗∗”.

POWER ON (po) “RESET” key on front panel of the NCU moduleor disconnection and reconnection of power supplyof softkey “NCK Reset”

NEW_CONF (cf) – Softkey “Set MD active” on MMC– “RESET” key on control unit, – Changes can be made in program mode at block

limits

RESET at end of program M2/M30

RESET (re) “RESET” key on control unit or

Immediately (im) after entry of the value

The levels of effectiveness have been listed above in order of priority.

Protection levels 0 to 7 have been used. The lock for protection levels 0 to 3 (4to 7) can be cancelled by entering the correct password (setting correct key-switch position). The operator has access to the information on the level towhich he has authorization and to all lower levels.

Meanings of numbers0 or 10: SIEMENS1 or 11: OEM-HIGH2 or 12: OEM-LOW3 or 13: End user4 or 14: Keyswitch position 35 or 15: Keyswitch position 26 or 16: Keyswitch position 17 or 17: Keyswitch position 0

The unit is referred to the default setting of machine data SCALING_FACTOR_USER_DEF_MASK andSCALING_FACTOR_USER_DEF.If the MD is not based on any physical unit, then the field is labelled with “–”.

Selectable data sets associated with one parameter.

Default setting

Value range(minimum andmaximum value)

Effectiveness ofchanges

Protection level

Unit

Index



02.99



The following data types are used in the control system:

BOOLEAN Machine data bit (1 or 0)

BYTE Integers (from –128 to +127)

DOUBLE Real values or integers(from +/–4.19*10–307 to +/–1.67*10308)

DWORD Integers (from –2.147*109 to +2.147*109)

STRING Character string (max. 16 characters) consisting ofcapital letters with digits and underscore

UNSIGNED WORD Integers (from 0 to 65536)

SIGNED WORD Integers (from –32768 to 32767)

UNSIGNED DWORD Integers (from 0 to 4294967300)

SIGNED DWORD Integers (from –2147483650 to 2147483649)

WORD Hex values (from 0000 to FFFF)

DWORD Hex values (from 00000000 to FFFFFFFF)

FLOAT DWORD Real values (from “8.43*10-37 to “3.37*1038)

Data type



08.99

02.99


0.0

Max

.

5131

5132

5133

FLO

AT

FLO

AT

FLO

AT

Cyl

inde

r pi

ston

dia

met

er

Cyl

inde

r pi

ston

rod

dia

met

er A

Cyl

inde

r pi

ston

rod

dia

met

er B

4.8

4.8

4.8

Pow

er O

n

Pow

er O

n

Pow

er O

nm

m

500.

0

500.

0

500.

0

0.0

0.0

0.0

0.0

0.0

CY

LIN

DE

R_P

ISTO

N_D

IAM

ET

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CY

LIN

DE

R_R

OD

_A_D

IAM

ET

ER

CY

LIN

DE

R_R

OD

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IAM

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ER

mm

mm

1.01

1.01

1.01

5008

5011

5012

5021

FLO

AT

UN

S.W

OR

D

UN

S.W

OR

D

WO

RD

Enc

oder

pha

se e

rror

com

pens

atio

n

Act

ual-v

alue

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sing

con

figur

atio

n

Fun

ctio

n sw

itch

Mul

ti-tu

rn r

esol

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n ab

solu

te e

ncod

er in

mot

or

4.10

4.10

4.12

4.10

Imm

edia

tely

Pow

er O

n

Imm

edia

tely

Pow

er O

n

Deg

rees

HE

X

HE

X

U

20.0

6553

5

6553

5

6553

5

0.0 0 4 4096

-20.

0

0 0

0000

EN

C_P

HA

SE

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RO

R_C

OR

RE

CT

ION

AC

TU

AL_

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ON

FIG

FU

NC

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H

EN

C_A

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RN

S_M

OTO

R

1.01

1.01

1.01

1.01

5023

5024

WO

RD

UN

S.W

OR

D

UN

S.D

WO

RD

5022

Mea

surin

g st

eps

of a

bsol

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trac

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mot

or

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eas.

circ

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or a

bs. t

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ar s

cale

gra

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4.10

4.10

4.10

Pow

er O

n

Imm

edia

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Pow

er O

n

– – nm

6553

5

BF

FF

5000

000

8192

0

2000

0

0000 0

1000

EN

C_A

BS

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SO

L_M

OTO

R

EN

C_A

BS

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GN

OS

IS_M

OTO

R

DIV

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N_L

IN_S

CA

LE

1.01

1.01

1.01

5100

5101

FLO

AT

FLO

AT

FLO

AT

5102

Mod

ulus

of e

last

icity

of h

ydra

ulic

flui

d

Sys

tem

pre

ssur

e

Pilo

t pre

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4.6

4.6

4.7

Imm

edia

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Pow

er O

n

Imm

edia

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bar

bar

bar

2100

0

350.

0

250.

0

1100

0

0.0

0.0

1000

0.0

0.0

FLU

ID_E

LAS

TIC

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DU

LUS

WO

RK

ING

_PR

ES

SU

RE

PIL

OT

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ER

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SS

UR

E

1.01

1.01

1.01

5001

UN

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OR

DV

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ity c

ontr

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r cy

cle

4.3.

2P

ower

On

164

2S

PE

ED

CT

RL_

CY

CLE

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E31

.25

1.01

µs

MD

No

.N

ame

in N

CS

ect.

war

eve

rsio

nU

nit

Att

rib

ute

sF

irm

-

5106

5107

5108

5109

5110

5111

5112

5113

5114

5115

UN

S.W

OR

D

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

UN

S.W

OR

D

FLO

AT

Dat

a ty

pe

Val

ve c

ode

num

ber

Rat

ed v

alve

flow

Rat

ed p

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ure

drop

of v

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ed v

olta

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f val

ve

Val

ve k

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poin

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Val

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ow r

atio

bet

w. A

and

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Nat

ural

freq

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val

ve

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e-po

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olta

ge o

f val

ve

Val

ve c

onfig

urat

ion

Val

ve d

ampi

ng

Ind

exE

ffec

tive

4.7

4.7

4.7

4.7

4.7

4.7

4.7

4.7

4.7

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

–

l/min

bar

V % – Hz

% HE

X

–

2000

1000

.0

200.

0

15.0

95.0

2.0

1000

.0

95.0

13 1.0

Vers

ion

0 0.0

35.0

10.0

10.0

1.0

150.

0

10.0 0 0.8

Min

.

0 0.0

1.0

0.5

0.2

0.5

1.0

0.2 0 0.4

VA

LVE

_CO

DE

VA

LVE

_NO

MIN

AL_

FLO

W

VA

LVE

_NO

MIN

AL_

PR

ES

SU

RE

VA

LVE

_NO

MIN

AL_

VO

LTA

GE

VA

LVE

_DU

AL_

GA

IN_F

LOW

VA

LVE

_FLO

W_F

AC

TOR

_A_B

VA

LVE

_NAT

UR

AL_

FR

EQ

UE

NC

Y

VA

LVE

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AL_

GA

IN_V

OLT

AG

E

VA

LVE

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NF

IGU

RAT

ION

VA

LVE

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MP

ING

Nam

e in

pla

inte

xt

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

FLO

AT

5040

FLO

AT

Pis

ton

zero

in r

elat

ion

to m

achi

ne z

ero

4.10

Imm

edia

tely

mm

1000

00.0

0.0

–100

0000

.0P

ISTO

N_Z

ER

O1.

01

4.6

1.01

5134

5135

FLO

AT

FLO

AT

Pis

ton

stro

ke

Cyl

inde

r de

ad v

olta

ge A

end

4.8

4.8

Imm

edia

tely

Imm

edia

tely

mm

ccm

3000

.0

2000

00.0

0.0

0.0

0.0

0.0

PIS

TON

_ST

RO

KE

CY

LIN

DE

R_D

EA

D_V

OLU

ME

_A

1.01

1.01

5004

UN

S.W

OR

DC

onfig

urat

ion

stru

ctur

e4.

3.1

Pow

er O

n10

0010

000

CT

RL_

CO

NF

IGH

EX

1.01

Ch

ap./



08.99

02.99



MD

No

.N

ame

in N

CS

ect.

war

eve

rsio

nM

ax.

Un

itA

ttri

bu

tes

Fir

m-

5140

5141

5142

5143

5150

5151

5152

5160

5161

5200

5201

UN

S.W

OR

D

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

UN

S.W

OR

D

FLO

AT

FLO

AT

UN

S.W

OR

D

UN

S.W

OR

D

Dat

a ty

pe

Val

ve-c

ylin

der

conn

ectio

n co

nfig

urat

ion

Pip

e le

ngth

at A

end

Pip

e le

ngth

at B

end

Inte

rnal

pip

e di

amet

ers

at A

and

B

Mov

ed d

rive

mas

s

Cyl

inde

r m

ount

ing

posi

tion

refe

rred

to A

end

Cyl

inde

r m

ount

ing

met

hod

Min

. nat

ural

freq

uenc

y pi

ston

pos

ition

Driv

e da

mpi

ng

Con

trol

out

put f

ilter

type

in v

eloc

ity c

ontr

olle

r

Ind

exE

ffec

tive

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.3.

2

4.3.

2

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

HE

X

mm

mm

mm

kg Deg

r.

– mm – ––

1

1000

0.0

1000

0.0

100.

0

2000

0.0

90.0 1

3000

.0

1.0 32

Vers

ion

0 0.0

0.0

5.0

0.0

0.0 0 0.0

0.1 00

Min

.

0 0.0

0.0

0.0

0.0

-90.

0 0 0.0

0.01 00

VA

LVE

_CY

LIN

DE

R_C

ON

NE

CT

ION

PIP

E_L

EN

GT

H_A

PIP

E_L

EN

GT

H_B

PIP

E_I

NN

ER

_ D

IAM

ET

ER

_A_B

DR

IVE

_MA

SS

CY

LIN

DE

R_A

_OR

IEN

TAT

ION

CY

LIN

DE

R_F

AS

TE

NIN

G

PIS

TON

_PO

S_M

IN_N

AT_F

RE

Q

DR

IVE

_DA

MP

ING

OU

TP

UT

_VC

TR

L_F

ILT

ER

_CO

NF

IG

Nam

e in

pla

inte

xt

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

Num

ber

of c

ontr

ol o

utpu

t filt

ers

in v

eloc

ity c

ontr

olle

rN

UM

_OU

TP

UT

_VC

TR

L_F

ILT

ER

S

FLO

AT

FLO

AT

5163

5164

Nat

ural

freq

uenc

y of

driv

e B

4.9

4.9

Imm

edia

tely

Imm

edia

tely

Hz

Hz

2000

.0

2000

.0

1.0

1.0

1.0

1.0

DR

IVE

_NAT

UR

AL_

FR

EQ

UE

NC

Y

DR

IVE

_NAT

UR

AL_

FR

EQ

UE

NC

Y_B

1.01

1.01

Nat

ural

freq

uenc

y of

driv

e

FLO

AT

5162

4.9

Imm

edia

tely

Hz

2000

.01.

01.

0D

RIV

E_N

ATU

RA

L_F

RE

QU

EN

CY

_A1.

01N

atur

al fr

eque

ncy

of d

rive

A

FLO

AT

5180

4.9

Imm

edia

tely

–1.

00.

70.

2C

LOS

ED

_LO

OP

_SY

ST

EM

_DA

MP

ING

1.01

Sel

ecte

d da

mpi

ng fo

r cl

osed

-loop

sys

tem

FLO

AT

5202

5203

5210

5211

5212

FLO

AT

FLO

AT

FLO

AT

FLO

AT

Num

erat

or b

andw

. con

tr. o

utpu

t filt

er 1

vel

. con

tr.

Dam

ping

con

trol

out

put f

ilter

1 v

eloc

ity c

ontr

olle

r

Nat

ur. f

req.

con

trol

out

put f

ilter

1 v

eloc

ity c

ontr

olle

r

Ban

dwid

th c

ontr

ol o

utpu

t filt

er 1

vel

ocity

con

trol

ler

Blo

ckin

g fr

eq. c

ontr

ol o

utpu

t filt

er 1

vel

ocity

con

tr.

4.3.

2

4.3.

2

4.3.

2

4.3.

2

4.3.

2

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

0...7

0...7

0...7

Hz

–Hz

Hz

Hz

7999

.0

1.0

8000

.0

7999

.0

7999

.0

0.0

1.0

1000

.0

500.

0

3500

.0

0.0

0.05

10.0

5.0

1.0

OU

TP

UT

_VC

TR

L_F

IL_1

_BW

_NU

M

OU

TP

UT

_VC

TR

L_F

IL_1

_DA

MP

OU

TP

UT

_VC

TR

L_F

IL_1

_FR

EQ

OU

TP

UT

_VC

TR

L_F

IL_1

_BW

OU

TP

UT

_VC

TR

L_F

IL_1

_SU

P_F

RE

Q

1.01

1.01

1.01

1.01

1.01

5204

5205

FLO

AT

FLO

AT

Dam

ping

con

trol

out

put f

ilter

2 v

eloc

ity c

ontr

olle

r

Nat

ur. f

req.

con

trol

out

put f

ilter

2 v

eloc

ity c

ontr

olle

r

4.3.

2

4.3.

2

Imm

edia

tely

Imm

edia

tely

0...7

0...7

–Hz

1.0

8000

.0

1.0

1000

.0

0.05

10.0

OU

TP

UT

_VC

TR

L_F

IL_2

_DA

MP

OU

TP

UT

_VC

TR

L_F

IL_2

_FR

EQ

1.01

1.01

5213

5214

FLO

AT

FLO

AT

Ban

dwid

th c

ontr

ol o

utpu

t filt

er 2

vel

ocity

con

trol

ler

Blo

ckin

g fr

eq. c

ontr

ol o

utpu

t filt

er 2

vel

ocity

con

tr.

4.3.

2

4.3.

2

Imm

edia

tely

Imm

edia

tely

0...7

0...7

Hz

Hz

7999

.0

7999

.0

500.

0

3500

.0

5.0

1.0

OU

TP

UT

_VC

TR

L_F

IL_2

_BW

OU

TP

UT

_VC

TR

L_F

IL_2

_SU

P_F

RE

Q1.

01

1.01

FLO

AT

5215

Num

erat

or b

andw

. con

tr. o

utpu

t filt

er 2

vel

. con

tr.4.

3.2

Imm

edia

tely

0...7

Hz

7999

.00.

00.

0O

UT

PU

T_V

CT

RL_

FIL

_2_B

W_N

UM

1.01

5230

5231

FLO

AT

FLO

AT

Wei

ght f

orce

lim

itatio

n

For

ce li

mita

tion

tole

ranc

e th

resh

old

abou

t wei

ght

4.4.

1

4.4.

1

Imm

edia

tely

Imm

edia

tely

0...7

0...7

NN10

0000

000.

0

0.0

1000

0.0

0.0

FO

RC

E_L

IMIT

_WE

IGH

T

FO

RC

E_L

IMIT

_TH

RE

SH

OLD

1.01

1.01

–100

0000

00.0

1000

0000

0.0

5136

FLO

AT

Cyl

inde

r de

ad v

olta

ge B

end

4.8

Imm

edia

tely

ccm

2000

00.0

0.0

0.0

CY

LIN

DE

R_D

EA

D_V

OLU

ME

_B1.

01

Ch

ap./



08.99

02.99


MD

No

.N

ame

in N

CS

ect.

war

eve

rsio

nM

ax.

Un

itA

ttri

bu

tes

Fir

m-

Dat

a ty

pe

Ind

exE

ffec

tive

Vers

ion

Min

.N

ame

in p

lain

text

5401

5402

FLO

AT

FLO

AT

Max

imum

use

ful v

eloc

ity

Bra

king

tim

e fo

r co

ntro

ller

disa

ble

4.3.

1

4.12

Pow

er O

n

Imm

edia

tely

1200

00.0

1200

00.0

0.0

0.0

0.0

0.0

DR

IVE

_MA

X_S

PE

ED

SP

EE

D_C

TR

L_D

ISA

BLE

_STO

PT

IME

mm

/min

ms

1.01

1.01

FLO

AT

5233

5234

FLO

AT

FLO

AT

5235

Fric

tion

forc

e at

vel

ocity

>0

Cut

off l

imit

stat

ic fr

ictio

n

Fric

tion

forc

e at

vel

ocity

<0

4.4.

2

4.4.

2

4.4.

2

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

N% N

1000

0000

0.0

100.

0

100.

0

40.0

–100

.0

–100

0000

00.0

3.0

ST

ICT

ION

_FO

RC

E_P

OS

ST

ICT

ION

_CO

MP

_TH

RE

SH

OLD

ST

ICT

ION

_FO

RC

E_N

EG

1.01

1.01

1.01

5240

5241

5242

5243

FLO

AT

UN

S.W

OR

D

FLO

AT

FLO

AT

For

ce c

ontr

olle

d co

ntro

lled-

syst

em g

ain

For

ce c

ontr

olle

r co

nfig

urat

ion

For

ce c

ontr

olle

r P

gai

n

Red

uctio

n of

forc

e co

ntro

ller

P g

ain

4.4.

3

4.4

4.4.

3

4.4.

3

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

– %

6

1000

0.0

100.

0

0.0 0 0.0

40.0

0.0 0 0.0

0.1

FO

RC

EC

ON

TR

OLL

ED

_SY

ST

EM

_GA

IN

FO

RC

EC

TR

L_C

ON

FIG

FO

RC

EC

TR

L_G

AIN

FO

RC

EC

TR

L_G

AIN

_RE

D

N/V

HE

X

1.01

1.01

1.01

1.01

5244

FLO

AT

For

ce c

ontr

olle

r re

set t

ime

4.4.

3Im

med

iate

ly0.

..7m

s20

00.0

40.0

0.0

FO

RC

EC

TR

L_IN

TE

GR

ATO

R_T

IME

1.01

5245

FLO

AT

For

ce c

ontr

olle

r sm

ooth

ing

time

cons

tant

4.4.

3Im

med

iate

ly0.

..7m

s10

0.0

0.5

0.25

FO

RC

EC

TR

L_P

T1_

TIM

E1.

01

5246

FLO

AT

For

ce c

ontr

olle

r D

-act

ion

time

4.4.

3Im

med

iate

ly0.

..7m

s10

000.

00.

0–1

0000

.0F

OR

CE

CT

RL_

DIF

F_T

IME

1.01

1000

0000

0.0

–100

0000

00.0

1000

0000

0.0

UN

S.W

OR

D

5247

5260

FLO

AT

UN

S.W

OR

D52

61

NU

M_F

FW

_FC

TR

L_F

ILT

ER

S

Fee

dfor

war

d co

ntro

l fac

tor

for

forc

e co

ntro

ller

FF

W_F

CT

RL_

FIL

TE

R_T

YP

E

4.4.

3

4.4.

3

4.4.

3

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

–% –

1

120.

0

0

100.

0

0

00.0

No.

of f

orce

con

trol

ler

feed

forw

ard

cont

rol f

ilter

s

FO

RC

E_F

FW

_WE

IGH

T

Type

of f

eedf

orw

ard

cont

rol f

ilter

in fo

rce

cont

rolle

r

1.01

1.01

1.01

5264

5265

5268

5269

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FF

W_F

CT

RL_

FIL

_1_F

RE

Q

FF

W_F

CT

RL_

FIL

_1_D

AM

P

FF

W_F

CT

RL_

FIL

_1_S

UP

_FR

EQ

FF

W_F

CT

RL_

FIL

_1_B

W

4.4.

3

4.4.

3

4.4.

3

4.4.

3

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

0...7

0...7

Hz

Hz

1.0

7999

.0

7999

.0

2000

.0

0.7

3500

.0

500.

0

10.0

0.2

10.0

5.0

PT

2 na

tur.

freq

. fee

dfor

war

d co

ntro

l filt

er1

PT

2 da

mpi

ng fo

r fe

edfo

rwar

d co

ntro

l filt

er 1

Blo

ckin

g fr

eque

ncy

of fe

edfo

rwar

d co

ntro

l filt

er 1

Ban

dwid

th o

f fee

dfor

war

d co

ntro

l filt

er 1

Hz

–

1.01

1.01

1.01

1.01

5270

FLO

AT

FF

W_F

CT

RL_

FIL

_1_B

W_N

UM

4.4.

3Im

med

iate

ly0.

..7H

z79

99.0

0.0

0.0

Num

erat

or b

andw

idth

feed

forw

ard

cont

rol f

ilter

11.

01

5280

UN

S.W

OR

DN

UM

_OU

TP

UT

_FIL

TE

RS

4.5.

2Im

med

iate

ly0.

..7–

10

0N

umbe

r of

con

trol

out

put f

ilter

s1.

01

5281

UN

S.W

OR

DO

UT

PU

T_F

ILT

ER

_TY

PE

4.5.

2Im

med

iate

ly0.

..7–

10

0Ty

pe o

f con

trol

out

put f

ilter

1.01

10

8000

.0

5285

5288

5289

FLO

AT

FLO

AT

FLO

AT

OU

TP

UT

_FIL

_1_D

AM

P

OU

TP

UT

_FIL

_1_S

UP

_FR

EQ

OU

TP

UT

_FIL

_1_B

W

4.5.

2

4.5.

2

4.5.

2

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

0...7

Hz

1.0

7999

.0

7999

.0

1.0

3500

.0

500.

0

0.05

1.0

5.0

Dam

ping

con

trol

out

put f

ilter

1

Blo

ckin

g fr

eque

ncy

cont

rol o

utpu

t filt

er 1

Ban

dwid

th c

ontr

ol o

utpu

t filt

er 1

– Hz

1.01

1.01

1.01

5284

FLO

AT

OU

TP

UT

_FIL

_1_F

RE

Q4.

5.2

Imm

edia

tely

0...7

Hz

8000

.010

00.0

10.0

Nat

ural

freq

uenc

y co

ntro

l out

put f

ilter

11.

01

5290

FLO

AT

OU

TP

UT

_FIL

_1_B

W_N

UM

4.5.

2Im

med

iate

ly0.

..7H

z79

99.0

0.0

0.0

Num

erat

or b

andw

idth

con

trol

out

put f

ilter

11.

01

5232

FLO

AT

Vel

ocity

thre

shol

d fo

r st

atic

fric

tion

4.4.

2Im

med

iate

lym

m/m

in50

0.0

10.0

0.0

ST

ICT

ION

_SP

EE

D_T

HR

ES

HO

LD1.

01

Ch

ap./



08.99

02.99



5414

5415

FLO

AT

FLO

AT

Nat

ural

freq

uenc

y of

ref

eren

ce m

odel

Ref

eren

ce m

odel

dam

ping

4.3.

2

4.3.

2

Imm

edia

tely

Imm

edia

tely

0...7

0...7

Hz –

1000

.0

1.0

150.

0

0.9

0.0

0.4

SP

EE

DC

TR

L_R

EF

_MO

DE

L_F

RE

Q

SP

EE

DC

TR

L_R

EF

_MO

DE

L_D

AM

PIN

G

1.01

1.01

5413

5409

UN

S.W

OR

D

FLO

AT

Sel

ectio

n of

vel

ocity

con

trol

ler

adap

tatio

n

Res

et ti

me

of v

eloc

ity c

ontr

olle

r

4.3.

2

4.3.

2

Imm

edia

tely

Imm

edia

tely

0...7

–ms

1

2000

.0

0

50.0

00.0

SP

EE

DC

TR

L_A

DA

PT

_EN

AB

LE

SP

EE

DC

TR

L_IN

TE

GR

ATO

R_T

IME

1.01

1.01

MD

No

.N

ame

in N

CS

ect.

war

eve

rsio

nM

ax.

Un

itA

ttri

bu

tes

Fir

m-

5430

5431

5440

5441

5460

5461

5462

5463

5464

5465

5466

5470

5475

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

5420

5421

WO

RD

Dat

a ty

pe

Max

. vel

ocity

for

setu

p m

ode

Tim

e co

nsta

nt o

f int

egra

tor

feed

back

Vel

ocity

con

trol

ler

smoo

thin

g tim

e co

nsta

nt

Vel

ocity

con

trol

ler A

D-a

ctio

n tim

e

Pos

itive

vel

ocity

set

poin

t lim

it

Neg

. vel

ocity

set

poin

t lim

it

Gra

dien

t of f

rictio

n co

mpe

nsat

ion

char

acte

ristic

Effe

ctiv

e ra

nge

of fr

ictio

n co

mpe

nsat

ion

Pis

ton

surf

ace

adap

tatio

n fa

ctor

, pos

itive

Kne

e-po

int c

ompe

nsat

ion

pos.

flow

Rou

ndin

g ra

nge

for

knee

-poi

nt c

ompe

nsat

ion

Pis

ton

surf

ace

adap

tatio

n fa

ctor

, neg

ativ

e

Kne

e-po

int c

ompe

nsat

ion

pos.

vol

tage

Man

ipul

ated

vol

tage

lim

itatio

n

Offs

et c

ompe

nsat

ion

Ind

exE

ffec

tive

4.3.

1

4.3.

2

4.3.

2

4.3.

2

4.3.

1

4.3.

1

4.3.

1

4.3.

1

4.5.

1

4.5.

1

4.5.

1

4.5.

1

4.5.

1

4.5.

3

4.5.

1

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

0...7

mm

/min

ms

ms

ms

mm

/min

mm

/min

% % % % %% % V–

1200

00.0

1000

.0

100.

0

100.

0

1200

00.0

1200

00.0

400.

0

10.0

200.

0

95.0

10.0

200.

0

95.0

10.0

4000

Vers

ion

10.0

0.0

0.0

0.25

0.0

0.0

0.0

0.1

100.

0

10.0

2.5

100.

0

10.0

10.00

Min

.

0.0

0.0

0.25 0.0

0.0

0.0

0.1

50.0

0.2

0.0

50.0

0.2

1.0

-400

0

DR

IVE

_MA

X_S

PE

ED

_SE

TU

P

SP

EE

DC

TR

L_IN

TE

GR

ATO

R_F

EE

DB

K

SP

EE

DC

TR

L_P

T1_

TIM

E

SP

EE

DC

TR

L_D

IFF

_TIM

E_A

PO

S_D

RIV

E_S

PE

ED

_LIM

IT

NE

G_D

RIV

E_S

PE

ED

_LIM

IT

FR

ICT

ION

_CO

MP

_GR

AD

IEN

T

FR

ICT

ION

_CO

MP

_OU

TP

UT

_RA

NG

E

AR

EA

_FA

CTO

R_P

OS

_OU

TP

UT

PO

S_D

UA

L_G

AIN

_CO

MP

_FLO

W

DU

AL_

GA

IN_C

OM

P_S

MO

OT

H_R

AN

GE

AR

EA

_FA

CTO

R_N

EG

_OU

TP

UT

PO

S_D

UA

L_G

AIN

_CO

MP

_VO

LTA

GE

OU

TP

UT

_VO

LTA

GE

_LIM

IT

OF

FS

ET

_CO

MP

EN

SAT

ION

Nam

e in

pla

inte

xt

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

1.01

FLO

AT

5433

FLO

AT

Vel

ocity

con

trol

ler

B D

-act

ion

time

4.3.

2Im

med

iate

lym

s10

0.0

0.0

-100

.0S

PE

ED

CT

RL_

DIF

F_T

IME

_B1.

01

FLO

AT

5467

Kne

e-po

int c

ompe

nsat

ion

neg.

flow

NE

G_D

UA

L_G

AIN

_CO

MP

_FLO

W

5406

FLO

AT

P g

ain

of v

eloc

ity c

ontr

olle

r A4.

3.2

Imm

edia

tely

0...7

%10

00.0

0.0

-100

.0S

PE

ED

CT

RL_

GA

IN_A

1.01

5407

FLO

AT

P g

ain

of v

eloc

ity c

ontr

olle

r4.

3.2

Imm

edia

tely

0...7

%10

00.0

0.0

-100

.0S

PE

ED

CT

RL_

GA

IN1.

01

5408

FLO

AT

P g

ain

of v

eloc

ity c

ontr

olle

r B

4.3.

2Im

med

iate

ly0.

..7%

1000

.00.

0-1

00.0

SP

EE

DC

TR

L_G

AIN

_B1.

01

5432

FLO

AT

Vel

ocity

con

trol

ler

lead

tim

e4.

3.2

Imm

edia

tely

ms

100.

00.

0-1

00.0

SP

EE

DC

TR

L_D

IFF

_TIM

E1.

01

5435

Con

trol

led

syst

em g

ain

4.3.

1Im

med

iate

lym

m/V

min

2000

0.0

0.0

0.0

CO

NT

RO

LLE

D_S

YS

TE

M_G

AIN

1.01

FLO

AT

-100

.0

5422

FLO

AT

Vel

ocity

thre

shol

d fo

r in

tegr

ator

feed

back

4.3.

2Im

med

iate

lym

m/m

in12

0000

.00.

010

.0F

EE

DB

K_S

PE

ED

_TH

RE

SH

OLD

1.01

5468

Kne

e-po

int c

ompe

nsat

ion

neg.

vol

tage

NE

G_D

UA

L_G

AIN

_CO

MP

_VO

LTA

GE

FLO

AT

4.5.

1Im

med

iate

ly%

95.0

10.0

0.2

1.01

FLO

AT

4.5.

1Im

med

iate

ly%

95.0

10.0

0.2

1.01

5404

FLO

AT

Pow

er d

isab

le ti

mer

4.12

Imm

edia

tely

ms

1000

0010

00

PO

WE

R_D

ISA

BLE

_DE

LAY

1.01

Ch

ap./



08.99

02.99


MD

No

.N

ame

in N

CS

ect.

war

eve

rsio

nM

ax.

Un

itA

ttri

bu

tes

5501

Fir

m-

5502

5506

5507

5514

5515

5516

5520

5530

5531

5532

FLO

AT

UN

S.W

OR

D

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

FLO

AT

UN

S.W

OR

D

UN

S.W

OR

D

UN

S.W

OR

D

Dat

a ty

pe

PT

1 tim

e co

nsta

nt fo

r ve

loci

ty fi

lter

1

Type

of v

eloc

ity fi

lter

PT

2 na

tura

l fre

quen

cy fo

r ve

loci

ty fi

lter

1

PT

2 da

mpi

ng fo

r ve

loci

ty fi

lter

1

Ban

d-st

op fi

lter

bloc

king

freq

uenc

y fo

r ve

l. fil

ter

1

Ban

d-st

op fi

lter

band

wid

th fo

r ve

loci

ty fi

lter

1

Num

erat

or b

andw

idth

for

velo

city

filte

r 1

Ban

d-st

op fi

lter

natu

ral f

requ

ency

for

velo

city

filte

r 1

Saf

ety

conf

igur

atio

n

Man

ipul

ated

var

iabl

e en

able

del

ay

Pow

er e

nabl

e de

lay

time

Ind

exE

ffec

tive

4.3.

1

4.3.

1

4.3.

1

4.3.

1

4.3.

1

4.3.

1

4.3.

1

4.3.

1

4.12

4.12

4.12

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

Imm

edia

tely

0...7

0...7

0...7

0...7

0...7

0...7

0...7

0...7

ms

Hz – Hz

Hz

Hz

% HE

X

ms

ms

500.

0

257

8000

.0

1.0

7999

.0

7999

.0

7999

.0

141.

0

31 500

300

Vers

ion

0.00

2000

.0

0.7

3500

.0

500.

0

0.0

100.

0

4 300

100

Min

.

0.00

10.0

0.2

10.0

5.0

0.0

1.0 0 0 0

SP

EE

D_F

ILT

ER

_1_T

IME

SP

EE

D_F

ILT

ER

_TY

PE

SP

EE

D_F

ILT

ER

_1_F

RE

QU

EN

CY

SP

EE

D_F

ILT

ER

_1_D

AM

PIN

G

SP

EE

D_F

ILT

ER

_1_S

UP

PR

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EQ

SP

EE

D_F

ILT

ER

_1_B

AN

DW

IDT

H

SP

EE

D_F

ILT

ER

_1_B

W_N

UM

ER

ATO

R

SP

EE

D_F

ILT

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02.99


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Ch

ap./



08.99

02.99





08.99

Notes


Hardware Drive Functions 5

02.99



5.1 Overview of interfaces

DACs

Measuring system(encoder connection)

Pressure sensor

Servo solenoidvalve

Drive bus

Device bus

Fig. 5-1 HLA closed-loop control plug-in module (2-axis)

5 Hardware Drive Functions


02.99


Axis 2F1901

Axis 1F1900

Fig. 5-2 Location diagram of HLA closed-loop control module



02.99



5.1.1 Measuring system

One position encoder for each axis can be evaluated on the module.

X101: Axis 1

X102: Axis 2

The measuring system must always be inserted in the connector of the associ-ated axis.

For further information, please see Section 7.1.

Table 5-1 PlugX101, X102; in each case15-pole subminiature D plug (two-tier)

Pin X101 X102 Function

1 PENC0 PENC2 Encoder power supply

2 M M Encoder power supply ground

3 AP0 AP2 Incremental signal A

4 AN0 AN2 Inverse incremental signal A

5 BMIDAT0 BMIDAT2 Data signal, EnDat interface

6 BP0 BP2 Incremental signal B

7 BN0 BN2 Inverse incremental signal B

8 XBMIDAT0 XBMIDAT2 Inverse data signal, EnDat interface

9 PSENSE0 PSENSE2 Remote Sense encoder power supply (P)

10 RP0 RP2 Incremental signal R

11 MSENSE0 MSENSE2 Remote Sense encoder power supply (M)

12 RN0 RN2 Inverse incremental signal R

13 M M Ground (for internal shields)

14 BMICLK0 BMICLK2 Clock signal, EnDat interface

15 XBMICLK0 XBMICLK2 Inverse clock signal, EnDat interface

Measuring systems



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5.1.2 Pressure sensors

Connection for 2 pressure sensors for each axis

X111: Axis 1 (sensor 1A, 1B)

X112: Axis 2 (sensor 2A, 2B)

Table 5-2 Connectors X111, X112; 15-pin subminiature D female connector in eachcase


1 P24DS P24DS Supply of pressure sensor with external +24 V voltage

2 P24DS P24DS Supply of pressure sensor with external +24 V voltage

3 – – Not assigned


5 M24EXT M24EXT Supply of pressure sensor with external 0 V voltage




9 M24EXT M24EXT Supply of pressure sensor with external 0 V voltage

10 M24EXT M24EXT Extra pin for jumper betw. pins 10–11 with 3-wire con-nection

11 PIST1BN PIST2BN Analog actual-value signal, reference ground

12 PIST1BP PIST2BP Analog actual-value signal, max. range 0...10 V

13 M24EXT M24EXT Extra pin for jumper betw. pins 13–14 with 3-wire con-nection

14 PIST1AN PIST2AN Analog actual-value signal, reference ground

15 PIST1AP PIST2AP Analog actual-value signal, max. range 0...10 V

The inputs are differential with 40 kΩ input resistance. The input voltage range is 0...+10 V.

The supply output has electronic short-circuit protection.The supply output is rated for a total current (4 sensors) of 200 mA.

Power supply of pressure sensors at 26.5 V 2 % according to external supply.



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5.1.3 Servo solenoid valve

X121: Axis 1

X122: Axis 2

Table 5-3 Connectors X121, X122; both are 15-pin subminiature D female connec-tors


1 P24RV1 P24RV2 +24 V switched




5 M M Electronics ground

6 USOLL1N USOLL2N Analog setpoint output, reference ground

7 USOLL1P USOLL2P Analog setpoint output +/–10 V


9 M24EXT M24EXT External 24 V ground





14 UIST1N UIST2N Analog valve actual-value input, reference ground

15 UIST1P UIST2P Analog valve actual-value input, +/–10 V

The analog valve actual value inputs are differential with 100 kΩ inputresistance.

The current ratings of the 24 V outputs on the servo solenoid value are

at ambient temperature 40 °C 2.0 A

at ambient temperature 55 °C 1.5 A

for the mean current value with a load cycle of 10 s duration.

The temperature corner points may be interpolated linearly.

The short-term current rating of the servo solenoid valve outputs is 3.0 A (200ms).

In the event of overload, fuse F1900 or F1901 on the HLA closed-loop controlplug-in module (for position, see Fig. 5-2) will blow.

The 24 V outputs switched for axes 1 and 2 are protected by miniature fuses,i.e. fuse type F1900 for axis 1 and F1901 for axis 2.

Value: 2.5 AF/250 V; 5x20 mm UL

Company: Wickmann-Werke GmbHAnnenstrasse 113D-58453 WittenorP.O. Box 2520D-58415 Witten, Germany

Order No.: 19194

Fuse protection



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5.1.4 Terminals

Shutoff valves (axis-specific), external 26.5 V supply, enabling, BERO inputs

X431: Axis 1

X432: Axis 2

Table 5-4 Connector X431; 8-pin Phoenix Combicon connector

Pin X431 Type1) Function Typ. voltage/limit values

1 M E Electronics ground

2 PV1 A +24V shutoff valve axis 1 max. 2.0 A

3 MV1 A Ground for shutoff valve for axis 1

4 C1 – Reserved, do not use!

5 P24 E Input for +24 V external 26.5 V 2 %

6 M24 E Input 0 V external

7 663 E Module-specific enable signal 21 V...30 V

8 9 A Internal +24 V enable voltage, term. 9

Table 5-5 Connector X432; 8-pin Phoenix Combicon connector

Pin X432 Type1) Function Typ. voltage/limit values

1 M E Electronics ground

2 PV2 A +24V shutoff valve axis 2 max. 2.0 A

3 MV2 A Ground for shutoff valve for axis 2

4 C2 – Reserved, do not use!

5 B1 E BERO input, axis 1 13 V...30 V

6 19 A Internal enable voltage ground, term.19

7 B2 E BERO input, axis 2 13 V...30 V

8 9 A Internal +24 V enable voltage, term. 9

Max. terminal cross-section 2.5 mm2.

The +24 V outputs for shutoff valves for axes 1 and 2 are short-circuit-proof.The energy absorbed when inductive loads are disconnected must be limited to1.7 J by the user (see also Section 2.4.2). When the supply polarity is reversed,the outputs are not protected against overload.

!Warning

If the polarity of the 24 V supply is reversed, then the shutoff valves will openimmediately, even if the NC or closed-loop control is not in operation!

1) E=input; A=output



04.00

02.99



Note

Each of the shutoff valves must be connected directly via 2 leads to pins 2/3 ofX431 or X432!

A current-compensated interference suppression coil is inserted at the input forthe external incoming supply terminal P24, terminal M24 (pins 5 and 6 ofX431).

Terminal M24 and terminal MV1/MV2 must therefore not be reversed or short-circuited.

The internal enabling voltage (terminal 9) is provided for the supply of BEROsand terminal 663 and must not be used to supply hydraulics components. Thehydraulics components must be supplied via incoming supply P24. The volt-ages may not be connected in parallel.

Module-specific enabling commands are issued by terminal 663. As no powersection is installed, no relay is available. The input is therefore evaluated viaoptocouplers in the HLA module and applied additionally to the shutoff valves. The enable voltage can be picked off at terminal 9.

Terminal 663 is referred to the internal enabling voltage (ground, terminal 19).

5.1.5 Test sockets (diagnosis)

Using the Start-Up Tool or an MMC102/103, it is possible to assign internal sig-nals to the test sockets on the 611D drive (in conjunction with SINUMERIK840D), where the signals are then available as analog values (see also Section3.11).

DAC1 DAC2

DAC3 Ground

Three 8-bit digital/analog converter (DAC) channels are available on the 611Dhydraulics module. An analog image of various drive signals can be connectedthrough to a test socket via these converters.

Only a window of the 24-bit wide drive signals can be displayed with the 8 bits(=1 byte) of the DAC, see Fig. 5-3. For this reason, the shift factor must be setto determine how fine the quantization of the selected signal must be. The nor-malization factor is calculated as the parameters are set and displayed as userinfo, e.g. 1V = 22.5A.

Enabling inputs

Test sockets

Scope of functions



04.00

02.99


SF = Shift factor

023Bit 781516 (LSB)

DAC with SF0

DAC with SF1

DAC with SF8

DAC with SF16

LSB = Least Significant Bit

Fig. 5-3 Representation of shift factor

The screen for activating and parameterizing the DAC outputs can be reachedfrom the basic machine display via softkeys Start-up / Drive/servo / DAC config.

The configuration is activated with Start. Active DACs are identified (active/inac-tive) on the left of the screen. The output is terminated with Stop (active/inac-tive) .

The selected signals are active after POWER ON.

The DAC operates on a voltage of between 0 V and +5 V. In this case, the 2.5 Voutput voltage corresponds to the zero of the displayed signal. A two’s comple-ment is used in the digital/analog conversion, see Fig. 5-3.

2.5V

+5V

0V

7FHex ( 0111 1111d)

80Hex (1000 0000d)

FFHex

00Hex

00Hex

UDAC

Fig. 5-4 Analog output voltage range

5.1.6 Bus interfaces

(see SIMODRIVE 611A/D)

X141: Input

X341: Output

A bus terminator must be inserted in the last module.

(see SIMODRIVE 611A/D)

X151: Device bus

Activation of analog output

Output voltagerange

Drive bus

Device bus



04.00

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5.2 System environment

The SINUMERIK 840D and HLA module are supplied via the device bus from the SIMODRIVE mains supply module or the SIMODRIVE monitoring mod-ule (may only be installed in conjunction with an NE module as an extendedpower supply). No provision has been made for any other type of voltage supplyand failure to use the supply provided could damage the unit.

Note

It is not permissible to operate an HLA module on its own on a SIMODRIVEmonitoring module!

Power is supplied to downstream electrical axes via the DC link busbars(40 mm2) of the carrier module.

For information about the electrical supply conditions for the NE or ÜW module,as well as circuit recommendations, technical data and setting options, pleaserefer to Section 2 and

References: /PJ2/ SIMODRIVE Planning Guide

SIMODRIVE

SIEMENS

NE module

Device bus

X101

X102

NCU(840D)

X35X34

X111X112X121X122

Bus terminator

Drive bus

HLA

Fig. 5-5 Component layout for hydraulic drive

Mains connection


5.2 System environment

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5.3 Additional information

5.3.1 Climatic and mechanical environmental conditions in operation

Note

The following information refers to the electrical section of the HLA.

IEC 68-2-1, IEC 68-2-2, IEC 68-2-3

If the specified values cannot be maintained, then a heat exchanger or air con-ditioner must be provided.

Table 5-6 Climatic environmental conditions

Temperature range Lower limit temperature 0°C

Upper limit temperature +55°C 1)

Dew-point temperature tdand relative air humidity U

Yearly average U = 75%, td = 17°C

On 30 days (24 hours) inyear (days distributed overthe annual period)

U = 95%, td = 24°C

On other days (<24 hours)(observing the yearly aver-age)

U = 85%, td = 20°C

Condensation Not permissible

Temperature change Within one hour 10 K

Within three minutes 1 K

Air pressure At installation site up to1500 m above sea level. Inthe case of higher heightvalues, the upper limit tem-perature must be reducedby 3.5°C/500m.

86 kPa to 108 kPa

Table 5-7 Mechanical environmental conditions

Vibration resistance(acc. to IEC 68-2-6)

Frequency range10–58 Hz

above 58–500 Hz

Constant deflection0.075 mmAmpl. of acceleration9.8 m/s2

Shock resistance in op-eration

Acceleration 5 geration (test group E, test Ea ac-cording to IEC 68, Part2-27)

Duration of nominal shock 11 ms for device withoutdisk drive30 ms for device with diskdrive

1) Current reduction above 40°C at the servo valve output, see Section 5.1.3.

Applicable standards

Climaticenvironmentalconditions



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5.3.2 Shipment and storage conditions

Note

The following information refers to the electrical section of the HLA.

IEC 68-2-1, IEC 68-2-2, IEC 68-2-3

The following data applies to modules in their original packaging:

Table 5-8 Climatic conditions

Temperature range Lower limit temperature –40°C

Upper limit temperature +70°C

Dew-point temperature tdand relative air humidity U

Yearly average U = 75%, td = 17°C


U = 95%, td = 24°C


U = 85%, td = 20°C

CondensationAs regards condensation,the following conditions mayapply simultaneously:

Seldom, brief, slight

Max. condensation period 3 hours

Frequency of condensation Yearly average: 3 / Max.: 10

Shortest sequence of con-densation cycles

1 day

Temperature change Within one hour 20 K

Air pressure The specified values applyto a shipment altitude of upto 3265 m above sea level

66 kPa to 108 kPa

Table 5-9 Mechanical conditions for shipment in original packaging

Vibration resistance (to IEC 68-2-6)

Frequency range5–9 Hz

above 9–500 Hz

Const. deflection3.5 mmAmpl. of acceleration10 m/s2

Applicable standards

Originallypackaged modules



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5.3.3 Resistance to pollutants

DIN 40046, Parts 36 and 37

Table 5-10 Harmful gases

Sulphur dioxide (SO2)Test conditions: Degree of severity 10 cm3/m3 0.3 cm3/m3

Temperature 25 °C 2 °C

Relative air humidity 75% 5%

Duration 4 days

Hydrogen sulfide (H2S)Test conditions: Degree of severity 1 cm3/m3 0.3 cm3/m3

Temperature 25 °C 2 °C

Relative air humidity 75% 5%

Duration 4 days

If the control is to be operated in an area exposed to harmful dust, it must beinstalled in a cubicle with heat exchanger or with an adequate supply of coolingair.

Relevant standards

Harmful dust



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Notes


Hydraulics Diagnostics

When an error occurs, the system reacts with either a power disable or velocitycontroller disable depending on the error type.

The power is disabled as a reaction to errors which might make operation underclosed-loop control impossible, such as

velocity controller at limit,

measuring system error,

RAM checkerror,

drive computer crash, etc.

The alarms which are specifically related to the hydraulics module are listedbelow:

Other alarms may also occur and are described in:

References: /DA/, Diagnostics Guide

For special cases arising in conjunction with an integrated PLC, please refer todocumentation of the SIMATIC S7-300 System.

The alarms are listed in order of ascending alarm number. There are gaps in thealarm numbering sequence. The sequence is not without gaps.

Each alarm, consisting of an alarm number and alarm text, is described with 4categories:

Explanation

Reaction

Remedy

To continue program

!Danger

Please check the situation in the plant on the basis of the description of theactive alarm(s). Eliminate the cause of the alarm(s) and give the appropriateacknowledgement. Failure to observe this warning will place your machine,workpiece, stored settings and possibly even your own safety at risk.

For a description of alarms with error numbers 300 000 to 300 499, pleaserefer to documentation

References: /DA/, Diagnostics Guide

Error reactions

Scope

Alarm order

Structure of alarmdescription

Safety

300 000 to300 499

6

02.99



Axis %1, drive %2 system error, error codes %3, %4

%1 = NC axis number%2 = drive number%3 = error code 1%4 = error code 2

The drive signals a system error. For an exact breakdown of error codes, see/FBA/ DB1, Operational Messages/Alarm Reactions.

NC not ready.Switchover for entire channel via MD might be possible.Channel not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

Please inform authorized personnel/service engineer.Re-initilization of drive.

The exact cause of the error can only be located by the development team. Thedevelopers must be notified of the displayed error identifiers.

SIEMENS AG, After-Sales Support for A&D MC Products, Hotline.

Switch control system OFF and ON again.

Axis %1, drive %2 measuring circuit error motor measuring system

%1 = NC axis number%2 = drive number

Signal level of motor encoder too small or noisy.

Mode group not ready.Switchover for entire channel via MD might be possible.Channel not ready.NC Start disable.NC Stop in response to alarm.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

Please inform authorized personnel/service engineer.Check encoder, encoder leads and connectors between drive motor and 611Dmodule: check for temporary interruptions (loose contact) – e.g. caused bymovements in cable tow.

Replace motor, encoder and/or cable if necessary

Check shield bond to front plate of closed-loop plug-in module (top screw)

Replace closed-loop control module

Check distance between gear wheel and sensor on gear wheel encoders(The HLA module does not feature a gear wheel encoder. This is a measur-ing system connected to the hydraulic equipment.).


300 500Explanation

Reaction

Remedy

To continueprogram

300 504Explanation

Reaction

Remedy

To continueprogram

6 Hydraulics Diagnostics

02.99


Axis %1, drive %2, no sign of life from NC


With the controllers enabled, the NC must update its sign of life in every positioncontroller cycle. The sign of life has not been updated in the event of a distur-bance.

Cause:a) NC no longer updates its sign of life in reaction to an alarm

(e.g. 611D alarm)b) Fault in communication link via the drive busc) Hardware fault on drive moduled) NC faulte) On 840D: Setting in machine data MD10082:

MN_CTRLOUT_LEAD_TIME (offset in setpoint transfer time)is too high

The alarm can be reconfigured in MD 11412: ALARM_REACTION_CHAN_NO-READY (channel not ready).

Mode group not readySwitchover for entire channel via MD might be possible.Channel not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

Please inform authorized personnel/service engineer.

Re: a) Check whether the sign of life failure is a secondary error. A secondaryerror is defined, for example, as:fault / alarm on axis x in an n-axis configuration. If the error is of this type, then the above error message is signalled for all n axes,even though the fault / alarm applies only to axis x.==> Eliminate cause of error on axis x==> Sign of life of other axes is irrelevant

Re: b) Check plug-in connections, take measures to suppress RI (check shielding, ground connections)

Re: c) Replace closed-loop control module

Re: d) See NC error diagnosis, replace NC hardware if necessary

Re: e) Set machine data 840D MD10082: CTRLOUT_LEAD_TIME (offset in setpoint transfer time) to correct value usingmachine data MD10083: CTRLOUT_LEAD_TIME_MAX (maximum settable offset in setpoint transfer time).


300 506Explanation

Reaction

Remedy

To continueprogram


02.99



Axis %1, drive %2 zero mark monitoring motor measuring system


Error in modulo (16/10) incrementation of encoder mark number on zero markercrossings. Increments have been lost or extra increments “trapped”.


Mode group not ready.Switchover for entire channel via MD might be possible.Channel not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

Please inform authorized personnel/service engineer. Use original Siemens pre-assembled encoder cables (high degree of shieldprotection). Check encoder, encoder cable for cable break and shield bonding point. Checkshield bonding point on front plate (top screw), replace closed-loop control mod-ule if necessary.Check distance between gear wheel and sensor on gear wheel encoders. If aBERO is installed, it is not the BERO signal which is monitored, but the zeromarker of the encoder.


Axis %1, drive %2 measuring function active


The measuring function (e.g. frequency response measurement) was active asthe power supply was connected (power-up).The function might have been started illegally.


Stop the measuring functionNCK Reset


300 508Explanation

Reaction

Remedy

To continueprogram

300 511Explanation

Reaction

Remedy

To continueprogram


02.99


Start-up required for axis %1, drive %2


This alarm occurs during initial start-up when no valid 611D machine data areavailable!

NC not ready.Mode group not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.


Boot the motor data

Back up the BOOT drive

Power up system again


Axis %1, drive %2 drive basic clock cycle invalid


The drive basic clock cycle set on the NC is too high for the drive.


No remedial measures need to be taken. After the system has powered upagain, the NCK machine data relevant to the drive basic clock cycle, i.e. MD 10050: SYSCLOCK_CYCLE_TIME (basic system cycle) and MD 10080:SYSCLOCK_SAMPL_TIME_RATIO (scale factor of position controller cycle foractual value sensing) are automatically altered so that the relevant limits areapplied.


Axis %1, drive %2 drive basic clock cycle axially unequal


The drive basic clock cycle is different for the two axes on a 2-axis module.

This alarm can only occur in connection with OEM users who are using a 611Ddrive without the standard NCK interface. In this instance, it is possible to trans-fer different axial drive clock cycles to the 611D modules.

300 701Explanation

Reaction

Remedy

To continueprogram

300 702Explanation

Reaction

Remedy

To continueprogram

300 707Explanation


02.99




Please inform authorized personnel/service engineer.Set drive basic clock cycle to the same value for both axes.


Axis %1, drive %2 position controller clock cycle axially unequal


The position controller clock cycle is different for the two axes on a 2-axis mod-ule.

This alarm can only occur in connection with OEM users who are using 611Ddrives without the standard NCK interface. In this instance, it would be possibleto transfer different axial position controller clock cycles to the 611D module.


Please inform authorized personnel/service engineer.Set position controller cycle to the same value for both axes.


Axis %1, drive %2 lead time for position controller invalid


The position controller computing time reduction specified by the NC must beshorter than the position controller cycle. The offset must be an integral multipleof the speed controller cycle.


Please inform authorized personnel/service engineer.Correct MD 10082: CTROUT_LEAD_TIME (offset in setpoint transfer time).


Reaction

Remedy

To continueprogram

300 710Explanation

Reaction

Remedy

To continueprogram

300 713Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 signal number var. signalling function invalid


The signal number for output of the appropriate signalling function is illegal. Thepermissible signal number range starts at 0 and ends at 29.


Please inform authorized personnel/service engineer.Enter the correct signal number.

Cancel alarm in all channels by pressing RESET key. Restart the part program.

Axis %1, drive %2 format error


The calculated filter coefficients for a bandstop cannot be represented in theinternal format.



Please inform authorized personnel/service engineer.Change the filter setting.Troubleshooting for the exact error cause can be supported by Hotline staff. CallSIEMENS AG, SIMODRIVE Hotline.


Axis %1, drive %2 save and boot necessary


After drive machine data have been modified, parameters need to be re-calcu-lated. The calculation routine is started with softkey CALCULATE. After the con-trol parameters have been calculated, the machine data must be saved and thesystem powered up again.


300 754Explanation

Reaction

Remedy

To continueprogram

300 770Explanation

Reaction

Remedy

To continueprogram

300 799Explanation


02.99



Switchover for entire channel via MD might be possible.NC not ready.Mode group not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

The newly calculated data must be saved (softkey: SAVE). The new parameter settings become operative when the system is next booted!


Axis %1, drive %2 signal number var. signalling function invalid


The signal number for output of the appropriate signalling function is illegal. Thepermissible signal number range starts at 0 and ends at 29.

Alarm display.Interface signals are set.

Enter the correct signal number.

Alarm display disappears with alarm cause. No further operator action required.

Axis %1, drive %2 meas. circuit error abs. track, code %3

%1 = NC axis number%2 = drive number%3 = error fine coding

Absolute encoder (EQN 1325)Monitoring of encoder hardware and EnDat interface.

Exact diagnosis via error code MD5023: ENC_ABS_DIAGNOSIS_MOTOR(diagnosis of absolute track in motor meas. circuit):

Bit No. Meaning Note

Bit 0 Lighting failure

Bit 1 Signal amplitude too low

Bit 2 Code connection faulty

Bit 3 Overvoltage

Bit 4 Undervoltage

Bit 5 Overcurrent

Bit 6 Battery must be replaced

Bit 7 CRC error (evaluate bit 13 as well) see 1)

Bit 8 Encoder cannot be usedIllegal assignment betweenabsolute and incremental tracks

Bit 9 C/D track on ERN1387 encoderfaulty or EQN encoder connected

Reaction

Remedy

To continueprogram

300 854Explanation

Reaction

Remedy

To continueprogram

310 505Explanation

6 Hydraulics Diagnostics 08.99

02.99


Bit No. NoteMeaning

Bit 10 Protocol cannot be interrupted

Bit 11 SSI level in data line detected

Bit 12 TIMEOUT on measured valuereading

Bit 13 CRC error (evaluate bit 7 as well) see 1)

Bit 14 Unassigned

Bit 15 Encoder defective

1) CRC error: Bits 7 and 13 Meaning:

0 1 CRC error from SIDA-ASIC1 0 Check byte error1 1 Error in correction of absolute track by

incremental track

Mode group not ready.Switchover for entire channel via MD might be possible.Channel not ready.NC Start disable.NC Stop in response to alarm.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.


Check encoder, encoder leads and connectors between drive motor and611D module: check for temporary interruptions (loose contact) – e.g.caused by movements in cable tow.-

Replace motor and cable if necessary

Incorrect cable type

Closed-loop control hardware unsuitable for Endat interface (e.g. closed-loop plug-in module with EPROM).


Axis %1, drive %2 valve is not responding


The valve is not following the valve spool setpoint.

Cause: Valve is not connected or has no valve spool checkback signal.


Response

Remedy

To continueprogram

310 607Explanation

Reaction


02.99



Valve without valve spool checkback: MD 5530: Reset bit 2;Check valve connections.

Cancel alarm in all channels of this mode group by pressing RESET key. Re-start the part program.

Axis %1, drive %2 velocity controller at limit


The velocity controller output has been at its limit for an impermissibly long pe-riod (MD 5605: SPEEDCTRL_LIMIT_TIME (time for velocity controller at limit)).

Monitoring function is active only if the velocity setpoint is lower than MD 5606: SPEEDCTRL_LIMIT_THRESHOLD (threshold for velocity controllerat limit).


Is the drive motor blocked?

Is the encoder connected? (check encoder cable).

Check shield on the encoder cable.

Encoder defective?

Check the encoder bar number.

Replace closed-loop control module.

Alter machine data MD 5605: SPEEDCTRL_LIMIT_TIME and MD 5606: SPEEDCTRL_LIMIT_THRESHOLD to match the mechanical and dynamicfeatures of the axis.


Remedy

To continueprogram

310 608Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 encoder limit frequency exceeded


Actual velocity is exceeding encoder limit frequency fg,max = 650 kHz.


Incorrect encoder connected?

Does setting in MD 5005: ENC_RESOL_MOTOR (no. of encoder marksmotor meas. system) match the encoder bar number?

Is the encoder cable connected correctly?

Is the shield of the encoder cable bonded over a large area?

Replace the encoder.

Replace the 611D hydraulics module.


Axis %1, drive %2 incorrect piston position


The error is activated in response to a negative actual position of the drive.Cause: Incorrect counting direction of actual position value at drive end.Piston zero has been incorrectly adjusted.If the drive is referenced and the offset between piston zero (piston limit stop atA end) and machine zero has been entered in MD 5040, then the piston posi-tion in MD 5741 may display only positive values (between zero and max. pis-ton stroke).


Correct counting direction of actual position value at drive end if:1. Pos. setpoint voltage (e.g. function generator) Cylinder piston moves from

A to BIf not: Invert control signal (change MD 5476 bit 0)

2. Cylinder piston moves from A to B v_act (MD 5707) > 0 If not: Invert actual value (change MD 5011 bit 0)

3. Check piston zero adjustment and correct if necessary:Set MD 5012 bits 14 and 15 to zero, save boot file, perform NCK Reset fol-lowed by reference point approach and then adjust the piston position.


310 609Explanation

Reaction

Remedy

To continueprogram

310 610Explanation

Reaction

Remedy

To continueprogram


02.99



Axis %1, drive %2 pressure sensor has failed


Force limitation or friction compensation is activated: MD 5241: Bit 0 or bit 1 isset and both actual pressures are less than 2 % of the system pressure in MD5101: WORKING_PRESSURE when the power is enabled.Cause: Defect in pressure sensor or connecting lead.


Check connections of the two pressure sensors.If pressure sensors are not installed:

Deactivate force limitation: MD 5241: Reset bit 0

Deactivate friction compensation: MD 5241: Reset bit 1


Axis %1, drive %2 force limitation off


The force limiting function is deactivated.Cause: The force limiting function is deactivated even though

the NC is specifying a force limit or

“Travel to fixed stop” is selected.


Switch on force limitation: MD 5241: Set bit 0


310 611Explanation

Reaction

Remedy

To continueprogram

310 612Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 invalid velocity controller cycle


An impermissible value has been set in the drive MD for the velocity controllerclock cycle MD 5001: SPEEDCTRL_CYCLE_TIME.

NC not readyChannel not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

Permissible: 62.5 µs T 500 µs


Axis %1, drive %2 invalid position controller clock cycle


The monitoring function on the 611D module has detected a position controllerclock cycle that is not within the permissible tolerance range.

The general conditions for obtaining a permissible clock cycle are:

1. Minimum clock time: 250 µs

2. Maximum clock time: 4 s

3. Position controller clock cycle must be a multiple of the velocity controllerclock cycle in drive MD 5001: SPEEDCTRL_CYCLE_TIME.


Change the position controller clock cycle on the NC


Axis %1, drive %2 invalid monitoring cycle


Monitoring cycle MD 5002: MONITOR_CYCLE_TIME (monitoring cycle) is in-valid.

310 701Explanation

Reaction

Remedy

To continueprogram

310 702Explanation

Response

Remedy

To continueprogram

310 703Explanation


02.99




See drive functions “FB / DB1”MD1002


Axis %1, drive %2 velocity controller clock cycle axially unequal


On 2-axis modules, the velocity controller clock cycle set in MD 5001:SPEEDCTRL_CYCLE_TIME must be identical for both axes.


Set velocity controller clock cycle in MD 5001: SPEEDCTRL_CYCLE_TIME toan identical value for both axes.


Axis %1, drive %2 monitoring cycle axially unequal


On 2-axis modules, the monitoring cycle set in MD 5002: MONITOR_CYCLE_TIME (monitoring cycle) must be identical for both axes.


Set MD 5002: MONITOR_CYCLE_TIME (monitoring cycle) to an identical valuefor both axes.


Reaction

Remedy

To continueprogram

310 704Explanation

Reaction

Remedy

To continueprogram

310 705Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 maximum useful velocity invalid


The high maximum velocity setting in drive MD 5401: DRIVE_MAX_SPEED andthe velocity controller clock cycle in MD 5001: SPEEDCTRL_CYCLE_TIME may cause a format overflow.


Reduce maximum useful velocity setting in MD 5401: DRIVE_MAX_SPEED orset a shorter velocity controller clock cycle in MD 5001: SPEEDCTRL_CYCLE_TIME.


Axis %1, drive %2 STS configuration axially unequal


On 2 axis modules, the configuration of the drive circuit MD 5003: STS_CON-FIG (STS configuration) must be set to an identical value for both axes.


Check drive MD 5003: STS_CONFIG (STS configuration) and set the bits forthe two axes on the module identically. (Do not change the default setting – itrepresents the optimum configuration).


Axis %1, drive %2 no. of encoder marks motor measuring system invalid


The number of encoder marks (bar number) for the motor measuring system setin MD 5005: ENC_RESOL_MOTOR (no. of encoder marks motor measuring system) is ei-ther zero or higher than the maximum input limit.

310 706Explanation

Reaction

Remedy

To continueprogram

310 707Explanation

Reaction

Remedy

To continueprogram

310 708Explanation


02.99




Match the number of encoder marks for the motor measuring system set in MD5005: ENC_RESOL_MOTOR (no. of encoder marks motor measuring system) to thebar number of the connected encoder. (Default setting for motor measuring sys-tem: 2 048 incr./rev).


Axis %1, drive %2 error in piston diameter or piston rod diameter


The piston diameter set in drive MD 5131: CYLINDER_PISTON_DIAMETER is less than zero

or

the piston rod diameter set in drive MD 5132: CYLINDER_PISTON_ROD_A_DIAMETER is greater than the piston diameterset in drive MD 5131: CYLINDER_PISTON_DIAMETER

or

the piston rod diameter set in drive MD 5133: CYLINDER_PISTON_ROD_B_DIAMETER is greater than the piston diameterset in drive MD 5131: CYLINDER_PISTON_DIAMETER


Enter a valid piston diameter setting in drive MD 5131: Enter CYLINDER_PISTON_DIAMETER (0 D 500 mm).

or

set the piston rod diameter in drive MD 5132: CYLINDER_PISTON_ROD_A_DIAMETER to a lower value than the piston di-ameter in drive MD 5131: CYLINDER_PISTON_DIAMETER.

or

set the piston rod diameter in drive MD 5133: CYLINDER_PISTON_ROD_B_DIAMETER to a lower value than the piston di-ameter in drive MD 5131: CYLINDER_PISTON_DIAMETER.


Reaction

Remedy

To continueprogram

310 709Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 distance-coded scale is incorrectly parameterized


When a distance-coded scale (MD 5011 bit 7=1) is selected, a linear measuringsystem must also be configured (MD 5011 bit 4=1).

NC not readyChannel not ready.NC Stop in response to alarm.NC Start disable.Alarm is displayed.Interface signals are set.

Check MD 5011: ACTUAL_VALUE_CONFIG (configuration of actual-valuesensing) and configure if necessary.


Axis %1, drive %2 feedforward control gain too high


The feedforward control gain is calculated from the reciprocal of the controlledsystem gain in drive MD 5435: CONTROLLED_SYSTEM_GAIN.

NC not readySwitchover for entire channel via MD might be possible.Channel not ready.NC Stop in response to alarm.NC Start disable.The NC switches to follow-up mode.Alarm is displayed.Interface signals are set.

Increase the velocity controller cycle in MD 5001:SPEEDCTRL_CYCLE_TIME.

Reduce the feedforward control factor of the force controller in MD 5247:FORCE_FFW_WEIGHT.

Increase the controlled system gain setting in MD 5435: CON-TROLLED_SYSTEM_GAIN.


Axis %1, drive %2 proportional gain of velocity controller too high


The P gain for the velocity controller is too high:

MD 5406: SPEEDCTRL_GAIN_A (gain at cylinder edge A end)

or

MD 5407: SPEEDCTRL_GAIN (gain for piston position with lowest naturalfrequency)

or

MD 5408: SPEEDCTRL_GAIN_B (gain at cylinder edge B end)

310 710Explanation

Reaction

Remedy

To continueprogram

310 750Explanation

Reaction

Remedy

To continueprogram

310 751Explanation

6 Hydraulics Diagnostics08.99

02.99




Enter a lower value for the P gain of the velocity controller:

MD 5406: SPEEDCTRL_GAIN_A (gain at cylinder edge A end)

or

MD 5407: SPEEDCTRL_GAIN (gain for piston position with lowest naturalfrequency)

or

MD 5408: SPEEDCTRL_GAIN_B (gain at cylinder edge B end)

Cancel alarm in all channels with RESET key. Restart the part program.

Axis %1, drive %2 I-action gain of velocity controller invalid


The I-action gain set in MD 5409: SPEEDCTRL_INTEGRATOR_TIME is notrepresentable.



Axis %1, drive %2 D component of velocity controller invalid


The D component of the velocity controller is too high:

MD 5431: SPEEDCTRL_DIFF_TIME_A (gain at cylinder edge A end)or

MD 5432: SPEEDCTRL_DIFF_TIME (gain for piston position with lowestnatural frequency) or

MD 5433: SPEEDCTRL_DIFF_TIME_B (gain at cylinder edge B end)

Reaction

Remedy

To continueprogram

310 752Explanation

Reaction

To continueprogram

310 753Explanation


02.99



Enter a lower value for the D component of the velocity controller:

MD 5431: SPEEDCTRL_DIFF_TIME_A (gain at cylinder edge A end)or

MD 5432: SPEEDCTRL_DIFF_TIME (gain for piston position with lowestnatural frequency) or

MD 5433: SPEEDCTRL_DIFF_TIME_B (gain at cylinder edge B end)


Axis %1, drive %2 friction compensation gradient too high


The friction compensation gradient set in MD 5460: FRICTION_COMP_GRADI-ENT is too high.


Reduce the gradient of the friction compensation in MD 5460: FRIC-TION_COMP_GRADIENT.


Axis %1, drive %2 area adaptation too high


The positive area adaptation factor set in drive MD 5462: AREA_FACTOR_POS_OUTPUT is too high or

the negative area adaptation factor set in drive MD 5463: AREA_FACTOR_NEG_OUTPUT is too high.

Reaction

Remedy

To continueprogram

310 754Explanation

Reaction

Remedy

To continueprogram

310 755Explanation


02.99




Select a lower setting for the positive area adaptation factor in MD 5462 AREA_FACTOR_POS_OUTPUT or

select a lower setting for the negative area adaptation factor in MD 5463 AREA_FACTOR_NEG_OUTPUT.


Axis %1, drive %2 controlled-system gain is less than/equal to zero


The controlled system gain setting in drive MD 5435: CONTROLLED_SYSTEM_GAIN is less than or equal to zero.


Enter a valid controlled system gain setting in drive MD 5435: CONTROLLED_SYSTEM_GAIN (see drive model data calculation).


Axis %1, drive %2 blocking frequency > Shannon frequency


The bandstop frequency set for a velocity or control output filter is higher thanthe Shannon sampling frequency defined by the sampling theorem.


Reaction

Remedy

To continueprogram

310 756Explanation

Reaction

Remedy

To continueprogram

310 757Explanation

Reaction


02.99


The blocking frequency in

drive MD 5514: SPEED_FILTER_1_SUPPR_FREQ or

drive MD 5210: OUTPUT_VCTRL_FIL_1_SUP_FREQ or

drive MD 5213: OUTPUT_VCTRL_FIL_2_SUP_FREQ or

drive MD 5268: FFW_FCTRL_FIL_1_SUP_FREQ or

drive MD 5288: OUTPUT_FIL_1_SUP_FREQ

must be lower than the reciprocal of two velocity controller clock cycles in MD 5001: SPEEDCTRL_CYCLE_TIME, i.e. less than 1/(2*MD 5001*31.25 microsec).


Axis %1, drive %2 natural frequency > Shannon frequency


The natural frequency of a velocity filter is higher than the Shannon samplingfrequency defined by the sampling theorem.


The natural frequency in Hz of a velocity must be less than the reciprocal of twovelocity controller clock cycles.

Velocity filter:

MD 5520 * 0.01 * MD 5514 < 1 / ( 2 * MD 5001 * 31.25 microsec)

BSF natural frequency MD 5520: SPEED_FILTER_1_BS_FREQ

BSF blocking frequency MD 5514: SPEED_FILTER_1_SUPPR_FREQ

Velocity controller clock cycle MD 5001: SPEEDCTRL_CYCLE_TIME


Remedy

To continueprogram

310 758Explanation

Reaction

Remedy

To continueprogram


02.99



Axis%1, drive%2 numerator bandwidth exceeds double blocking fre-quency


The numerator bandwidth of a velocity or control output filter is greater than 2xthe blocking frequency.

The error message is only generated for the general bandstop if the followingapplies:

Velocity filter 1:

MD 5516 > 0.0 or

MD 5520 <> 100.0

Control output filter 1 in velocity controller:

MD 5212 > 0.0


MD 5215 > 0.0


The numerator bandwidth must be less than twice the blocking frequency.

Velocity filter 1:

– BSF bandwidth numerator drive MD 5516: SPEED_FILTER_1_BW_NUMERATOR

– BSF blocking frequency drive MD 5514: SPEED_FILTER_1_SUPPR_FREQ

MD 5516 2 * MD 5514


– BSF numerator bandwidth drive MD 5212: OUTPUT_VCTRL_FIL_1_BW_NUM

– BSF blocking frequency drive MD 5210: OUTPUT_VCTRL_FIL_1_SUP_FREQ

MD 5212 2 * MD 5210


– BSF numerator bandwidth drive MD 5215: OUTPUT_VCTRL_FIL_2_BW_NUM

– BSF blocking frequency drive MD 5213: OUTPUT_VCTRL_FIL_2_SUP_FREQ

MD 5215 2 * MD 5213


310 759

Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 denominator bandwidth exceeds double natural fre-quency


The denominator bandwidth of a velocity filter is greater than 2x the natural fre-quency.

The error message is only generated for the general bandstop if the followingapplies:

Velocity filter 1:

MD 5516 > 0.0 or

MD 5520 <> 100.0


The denominator bandwidth of a velocity filter must be smaller than twice thenatural frequency.

Velocity filter 1:

BSF bandwidth drive MD 5515: SPEED_FILTER_1_BANDWIDTH

BSF blocking frequency drive MD 5514: SPEED_FILTER_1_SUPPR_FREQ

BSF natural frequency drive MD 5520: SPEED_FILTER_1_BS_FREQ

MD 5515 2 * MD 5514 * 0.01 * MD 5520


Axis %1, drive %2 proportional gain of force controller too high


The P gain of the force controller in MD 5242: FORCECTRL_GAIN is too high.


Enter a lower value for the force controller P gain in MD 5242: FORCECTRL_GAING.


310 760

Explanation

Reaction

Remedy

To continueprogram

310 761Explanation

Reaction

Remedy

To continueprogram


02.99



Axis %1, drive %2 I-action gain of force controller invalid


The integral gain in MD 5244: FORCECTRL_INTEGRATOR_TIME is notrepresentable.



Axis %1, drive %2 D component of force controller invalid


The D component of the force controller in MD 5246: FORCECTRL_DIFF_TIMEis too high.


Enter a lower value for the force controller D component in MD 5246: FORCECTRL_DIFF_TIME.


Axis %1, drive %2 force controller controlled-system gain is less than/equal to zero


The controlled-system gain setting for the force controller in drive MD 5240 FORCECONTROLLED_SYSTEM_GAIN is less than or equal to zero.


Enter a valid controlled-system gain setting in drive MD 5240FORCECONTROLLED_SYSTEM_GAIN (see Calculate Model Data).


310 762Explanation

Reaction

To continueprogram

310 763Explanation

Reaction

Remedy

To continueprogram

310 764

Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 gradient in fine range of valve characteristic is less thanzero


The gradient in the fine range of the valve characteristic is less than zero.


The gradient in the fine range is calculated according to the:

positive quadrant: (MD 5464–MD 5480)/(MD 5465–MD 5481)

negative quadrant: (MD 5467–MD 5483)/(MD 5468–MD 5484)

Enter a valid combination in the above drive MD.


Axis %1, drive %2 gradient in coarse range of valve characteristic is lessthan/equal to zero


The gradient in the coarse range of the valve characteristic is less than zero.


The gradient in the coarse range is calculated according to the:

positive quadrant: (MD 5485–MD 5464)/(MD 5486–MD 5465)

negative quadrant: (MD 5487–MD 5467)/(MD 5488–MD 5468)



310 771

Explanation

Reaction

Remedy

To continueprogram

310 772

Explanation

Reaction

Remedy

To continueprogram


02.99



Axis %1, drive %2 gradient at end of saturaton range of valve characteris-tic is less than/equal to zero


The gradient at the end of the saturation range of the valve characteristic is lessthan/equal to zero. The saturation range is rounded by a parabola function. Theparabola has a maximum in the saturation region and cannot therefore beinverted.


The gradient at the end of the saturation region is calculated according to the:

positive quadrant: 2(1.0–MD 5485)/(1.0–MD 5486)–(MD 5485–MD 5464)/(MD 5486–MD 5465)

negative quadrant: 2(1.0–MD 5487)/(1.0–MD 5488)–(MD 5487–MD 5467)/(MD 5488–MD 5468)



Axis %1, drive %2 overlap between zero and breakpoint ranges of valvecharacteristic


The zero range and breakpoint range of the valve characteristic are overlap-ping.


The zero and breakpoint ranges overlap if:

positive quadrant: (MD 5481+MD 5482)>(MD 5465–MD 5466)

negative quadrant: (MD 5484+MD 5482)>(MD 5468–MD 5466)



310 773

Explanation

Reaction

Remedy

To continueprogram

310 774

Explanation

Reaction

Remedy

To continueprogram


02.99


Axis %1, drive %2 overlap between breakpoint range and saturation re-gion of valve characteristic


The breakpoint range and saturation region of the valve characteristic are over-lapping.


The breakpoint range and saturation region overlap if:

positive quadrant: (MD 5465+MD 5466)>MD 5486

negative quadrant: (MD 5468+MD 5466)>MD 5488



310 775

Explanation

Reaction

Remedy

To continueprogram


02.99




Notes


Peripherals/Accessories

7.1 Measuring systems

7.1.1 Encoders, linear scales

Note

For connector assignments, see Section 5.1.1.

The HLA module is designed to evaluate

incremental measuring system with sinusoidal signals (A, B) and a refer-ence signal (R)

or

absolute measuring system with sinusoidal signals (A, B) and EnDat inter-face for absolute position sensing

with the following signal limit data:

Signalvolt-ages

0

UM(A)Track signal A

Mech. angle ϕDifferential signal (A – *A)

Signalvolt-ages

0

UM(B)

Mech. angle ϕ

Differential signal (B – *B)Signalvolt-ages

0

UM(R)

Mech. angle ϕ

Differential signal (R – *R)

Track signal *A

Track signal BTrack signal *B

Track signal RTrack signal *R

Fig. 7-1 Required waveform of measuring system signals for data definition

Encoder specification

7

02.99



0

Direct component UG(A)

Mech. angle ϕ

0Mech. angle ϕ

0 Mech. angle ϕ

Diff

eren

tial s

igna

l (A

– *

A)

Direct component UG(B)

Direct component UG(R)

Useful signal

Diff

eren

tial s

igna

l (B

– *

B)

Diff

eren

tial s

igna

l (R

– *

R)

β

45 degrees

Uniqueness range

α1 α2

360 degrees Electrical

Fig. 7-2 Required waveform of motor system signals (incremental and reference sig-nals) after differential amplification for data function

Table 7-1 Limit data of measuring system signals

Parameter Designation Min. Typ. Max. Unit

Mean voltage UM(A); UM(B); UM(R) 1.75 3.25 V

Amplitude A – *A; B – *B 350 500 600 mv

Ratio (A – *A)/(B – *B) 0.9 1.0 1.1 –

Dynamic change in amplitude ∆(A – *A)/360° el.; ∆(B – *B)/360° el. – – 0.3 mV/360° el.

Direct component UG(A)/amplitude (A – *A);UG(B)/amplitude (B – *B);

–0.2 0 +0.2

Dynamic change in direct component

∆UG(A)/360° el.; ∆UG(B)/360° el.

– – 1 mV/360° el.

Signal frequency fs – – 200 KHz

Phase displacement β 85 90 95 Degrees

Harmonic distortion1) k – – 1 %

Useful signal R – *R 300 – 1500 mV

DC voltage UG(R) –150 – –500 mV

Uniqueness range α1; α2 50 – 270 Degrees

1) Definition for harmonic distortion: k = U12+U22+...Un2

U0: Fundamental componentU1...Un: Harmonic components

7 Peripherals/Accessories


02.99


Note

If signals which do not conform to this specification are used, problems such asspeed ripple, positioning inaccuracy or other malfunctions may be encoun-tered.

When the encoder is parameterized, one of the options “Incremental” or “Abso-lute” (EnDat interface) must be selected in menu display “Measuring systemdata for HLA”.

The purpose of these options is to set the following drive machine data:

MD 5011: ACTUAL_VALUE_CONFIG (actual-value sensing configuration)

MD 5024: DIVISION_LIN_SCALE (linear scale graduations).

Table 7-2 MD 5011 assignments

Bit No. Meaning

Bit 0 1 = track inversion ON

Bit 1 1 = phase error compensation active

Bit 2 Not assigned

Bit 3 1 = absolute encoder (EnDat interface)

Bit 4 1 = linear measuring system

Bit 5 Reserved

Bit 6 Reserved

Bit 7 1 = distance-coded measuring system

Bit 8 1 = zero marker selection by NC (several zero markers)

Bits 9–11 Not assigned

Bit 12 Reserved

Bit 13 Reserved

Bits14/15

EnDat data transfer rate

Options



02.99



7.1.2 Connection diagrams

Hydraulicsmodule(HLA)

X101/X102

6FX2002 – 2CA11 – 1JJJ v 40 mIncremental en-coder 1 Vpp

6FX2002 – 2AD00 – 1JJJ v 40 m Linear absolute measuring system(EnDat)LC 181

Adapter cable1)

313 791

Direct linear in-cremental mea-suring systemLS 186

LS 486

Adapter cable1)

310 128

310 123

Fig. 7-3 Example showing connection options for measuring system cable

1) Cable can be ordered from supplier of linear scale.

Connection options



02.99


*B

Length according to length code

23

1

Sub D female connector, 15-pin, with screw lock

6FC9348-7HX

0.380.38

0.380.38

0.380.38

0.380.38

0.50.50.50.5

3

Measuring system

yegn

bkbn

buvt

rdog

wh-rdwh-bkwh-buwh-ye

*A

B

R*R

Trig/UasTrig

5V senseP encoder0V senseM encoder

5

4

7

9

2121110

6

8

1

3

Housing

Ua1

*Ua0

5V sense5V_encoder0V senseM_encoder

*Ua1

Ua2*Ua2

Ua0

HLA module

12

14

15

91

112

4

67

10

Housing

Item Meaning

12-pin connector

6FX2003-0CE12

Signal lead 4x2x0.38+4x0.5

6FX2008-1BD21

1

2

3

3

Order No. (MLFB) of measuring system lead: 6FX2002-2CA11-1

Pin 1 Cable print (order no., length in m, manufacturer, month/year of manufacture)

A

Z

Z 2:1

12

345

6

78 9

10

11

12

Fig. 7-4 Measuring system lead for encoder with voltage signals (X101/X102)



02.99



vt0.14

Clock cycle


23

1

Sub D female connector, 15-pin, with screw lock

6FC9348-7HX

3

Measuring system

yegn

bu

gyburdyebkwh-bk

A*A

*clock cycleP encoder5V senseM encoder0V sense

0.14

0.14

0.140.140.50.140.50.14

bk

0.14

0.14

*data

15

17

8971104

16

1213

14

Housing

Ua1

*data

Clock cycle*clock cycleP encoder5V senseM encoder0V sense

*Ua1

Ua2*Ua2

Data

HLA module

8

1415192

11

4

67

5

13

Housing

11

Item Meaning

17-pin connector

6FX2003-0CE17

Signal lead 3x2x0.14+4x0.14+2x0.5

6FX2008-1BD41

1

2

3

3

Order No. (MLFB) of lead: 6FX2002-2AD00-1

Pin 1 Cable print (order no., length in m, manufacturer, month/year of manufacture)

Data

1) 1)

1) Single screens bundled, connected to contactvia largest possible cross-sectional area.

B*B

0.14bn

Z

Z 2:1

12

3

45 6

78

91011

1213

14 15

1617

Fig. 7-5 Measuring system lead for encoder with voltage signals + EnDat (X101/X102)



02.99


7.2 BERO (X432)

Only BEROs of type 3-wire PNP NO contact may be used.

We recommend the following BERO models:

SIEMENS BERO M30 3RG 4014-0AG01

BERO M12 3RG 4012-3AG01

Note

The BERO cable must be shielded.

Table 7-3 Pin assignment X432

Terminal name Type1) Signal name

B1/B2 E BERO (external refrence system) axis 1/2

19 A Power supply for BERO ground external

9 A Power supply for BERO 24 V external

1) E: Input, A: Output


7.2 BERO (X432)

04.00

02.99



7.3 Pressure sensing

7.3.1 Sensors

Note

For connector assignments, see Section 5.1.2.

The task of pressure sensors is to convert mechanical quantity “pressure” intoElectrical quantity “voltage” or “current”.

The pressure sensors included in the Bosch hydraulic product range are suit-able for pressure monitoring and control applications in machine construction,on injection moulding machines, presses and many other areas.

The most important features of the sensors are

pressure sensor element consisting of high-quality steel membrane (springmaterial), coated with thin-layer strain gauges in full-bridge connection

integrated electronic circuitry with temperature compensation

signal output proportional to pressure

zero point and sensitivity are calibrated exactly by manufacturer

Note

Pressure sensor cables with pre-assembled sensor end are not available. Thefollowing cable information is intended only as an example.

Sensor must be mounted in vertical position with connector pointing down-wards.

The sensor must be installed in the hydraulic system in such a way as toprevent any air cushions from developing between the sensor membraneand the pressure medium.

Pressure medium: Hydraulic fluid; other fluids only after consultation withBosch.

Sensors with a signal voltage of U=0...10 V are available in the following vari-ants for the HLA module:

General

Instructions foruse

Selection of pressure sensor(recommendedtypes)



02.99


Table 7-4 Recommended types of pressure sensor

Signal Pressure range Connector Bosch order no.

0...10 V 100 bar Rectangular connector,4 i

0811 405 554

210 bar4-pin

0811 405 540

350 bar 0811 405 547

210 bar 7-pin circular connector 0811 405 531

350 bar 0811 405 532

73–1

12

12

15 47–1 22.5

O35

O18

.8

G1/

4”IS

O 2

28 A

13x2

Conduit thread 7

6.5

0.3 – 0.4 Nm32

MA=20+5 Nm

Ref. 0 V (signal)

Usig

0 V

Supply

4

3

2

1

P

U4 1

32

BO

SC

H

Fig. 7-6 Pressure sensors, order nos. 0811 405 540, 0811 405 547 and 0811 405 554

Dimensions/terminalassignments



02.99



12

12

15 43–1

O34

O18

.8

G1/

4”IS

O 2

28 A

13x2

32MA=20+5 Nm

Ref. 0 V (signal)

Usig

0 V

Supply1

2

3

4

P

U

BO

SC

H

5

6

7

Fig. 7-7 Pressure sensors, Order Nos. 0811 405 531 and 0811 405 532

Bosch Order No. 1834 484 141

7 P

IP 40

Fig. 7-8 Accessories for pressure sensors Order Nos. 0811 405 531 and 0811 405 532



02.99


Table 7-5 Characteristics of pressure sensors

Characteristic Value range

Signal voltage 0...10 V

Supply voltage

0811 405 510/0811 405 510 13...28 V DC

0811 405 510/0811 405 511 13...28 V DC

0811 405 523/0811 405 523 12...28 V DC

0811 405 523/0811 405 530 12...28 V DC

0811 405 523/0811 405 554 12...28 V DC

“Dynamic” overload capability 2 x pnom (up to 20 x 106 load cycle)

“Static” overload capability 3 x pnom (up to 10 x 0.5 sec each)

Burst pressure >1500 bar

Linearity deviation incl. hysteresisZero point dispersionSensitivity dispersionTemp. coefficient of zero pointTemp. coefficient of sensitivity

<0.5 %<0.5 %<0.5 %<0.2 %/10 °C<0.25 %/10 °C

Measurement temperature range (compen-sated)Operating temperature rangeStorage temperature range

+10 to +70 °C–10 to +80°C–30 to +90°C

Hydr. dead volumeMeasuring frequency (–3 dB)Natural frequencyMax. acceleration

Approx. 0.3 cm3

1 kHz10 kHz25 g (g=9.81 ms2)

Connecting piece material (hydr.)Membrane material

St 37 2 K DIN 1652 (chemically nickeled)X 5 CrNiCuNb 1744

Hydraulic connection G 1/4 (ISO 228)

For pressure sensors with order no.: 0811 405 5230811 405 5300811 405 554,

the 4-pin cube-shaped connector is supplied. Replacement connectors can beordered under no.: 1834 484 061 from Bosch.

Characteristics

Accessories



02.99



7.3.2 Connection diagrams

Note

The following cable data for hydraulics equipment apply for Bosch products. Ifhydraulics components supplied by other manufacturers are used, the pin as-signments of the hydraulic-end connections might be different!

PIST1AN


2 3

1

Sub D male connector, 15-pin, with screw lock UNC 4-406FC9341-1HC

0.180.180.180.18

bkbn

bn

rd

rd

og

og

P24DS

P24DS

PIST1AP

PIST1BP

2

2

1

1

3

3

4

4

Housing

Uext. 0 V

Uext. 0 V

Uext. 24 V

Uext. 24 V

Actual value, 0...10 V

Actual value, 0...10 V

Actual value, ground

Actual value, ground

HLA module

2

1

15

12

14

11

Item Meaning

4-pin or 7-pin female connector Order number as stated in Table 7-4, e.g. Bosch 1834484061 (connector included with pressure sensor).

Signal lead 2x(2x0.18) C6FX2008-1BD71

1

2

3

5

9

Order No. (MLFB) of signal lead for pressure sensors: 6FX2002-2AD00-1

Pin 1

Cable print (order no., length in m, manufacturer, month/year of manufacture)

M24EXT

M24EXT

Shield

Shield

A

B

A

B

1)

1)

PIST1BN

0.180.180.180.18

bk

Pressure sensor A or B

1) Shield insulated

Note: Max. approved system cable length 40 m

3

3

Fig. 7-9 Signal lead for pressure sensors (X111/X112)



02.99


7.4 Connection diagrams for servo solenoid valves

Note

The following cable data for hydraulics equipment apply specifically to Boschservo solenoid valves (directly and pilot actuated).

+24 V switched

UIST1N


2 3

1

Sub D male connector, 15-pin, with screw lock UNC 4-40

6FC9341-1HC

bkbn

wh-ye

rd

wh-bk

og

wh-bu

USOLL1N

P24RV1

UIST1P

M24EXT

D

A

EF

B

C

Housing

Setpoint output +/– 10 V

+24 V switched

Setpoint output, groundActual value input +/–10 V

External 24 V ground

Actual value input, ground


HLA module

6

3

15

10

14

9

Item Meaning

7-pin female connector

GE.570102.0144.00

Signal lead 4x(2x0.38) + 4x0.5 C

6FX2008-1BD21

1

2

3

7

4

Order No. (MLFB) of signal lead for 7-pin servo solenoid valve: 6FX2002-2BA00-1

Pin 1


USOLL1P

P24RV1

M24EXT

wh-rd



3

AFB

C ED

buvtyegn

0.38

0.38

0.5

0.38

0.5

0.38

0.5

0.38

Shield

0.5

0.380.380.38

Z

Z 2:1

Fig. 7-10 7-pin signal lead for servo solenoid valve (X121/X122) – standard version



02.99



Note

The pin assignments on valves supplied by other manufacturers may deviatefrom the assignments shown in Fig. 7-10. Cables must be assembled by thecustomer!

+24 V switched

UIST1N


2 3

1


6FC9341-1HC

bkbn

wh-ye

rd

wh-bk

og

wh-bu

USOLL1N

P24RV1

UIST1P

M24EXT

D

A

EF

B

C

Housing


+24 V switched





HLA module

6

3

15

10

14

9

Item Meaning


Valve-specific


6FX2008-1BD21

1

2

3

7

4

Pin 1


USOLL1P

P24RV1

M24EXT

wh-rd



3

AFB

C ED

buvtyegn

0.38

0.38

0.5

0.38

0.5

0.38

0.5

0.38

Shield

0.5

0.380.380.38

Z

Z 2:1

1

2

Fig. 7-11 Interconnection diagram for 7-pin servo solenoid valve (X121/X122) – connection option 2 (customized)



02.99


Note

The following cable data for hydraulics equipment apply specifically to BoschHRVs (directly and pilot actuated).

yeM24EXT External 24 V ground9

0.38vtP24RV1 +24 V switched

10.38

buP24RV1 +24 V switched2

0.38

+24 V switched

UIST1N


2 3

1


6FC9341-1HC

bkbn

wh-ye

rd

wh-bk

og

wh-bu

USOLL1N

P24RV1

UIST1P

M24EXT

4

1

56

2

7

Housing


+24 V switched





HLA module

6

3

15

11

14

10

Item Meaning


GE.570102.0145.00


6FX2008-1BD21

1

2

3

7

4

Order No. (MLFB) of signal lead for 12-pin servo solenoid valve: 6FX2002-2BA10-1

Pin 1


USOLL1P

P24RV1

M24EXT

wh-rd



3

gn

0.38

0.38

0.5

0.38

0.5

0.38

0.5

0.38

Shield

0.5

0.380.38

8

117

65 4

1

3

29

10

3910

Z

Z 2:1

Fig. 7-12 12-pin signal lead for servo solenoid valve (X121/X122)



02.99



Note

The following data for the connectors on the servo solenoid valve signal leadare required only for spare parts orders or pre-assembly of cables by the cus-tomer. The cables are normally supplied fully pre-assembled by Siemens.

AFB

C ED

28.6

10 2.6

Metal Crimp connection 0.08 Bosch1 834 482 023

Plastic Crimp connection 0.05 Bosch1 834 482 026

Plastic Soldered connection

0.05 Bosch1 834 482 022HirschmannCM 06 EA 14S-61S

Version Contacts kg Order No.

66

7 43

261

21.5 Approx. 66

Plastic Soldered connection

0.05 Bosch1 834 484 140Binder723-2-09-0126-25-07


Fig. 7-13 Dimension diagram of circular, 7-pin connector

29 79

Plastic Crimp connection 0.05 Bosch1 834 484 142HirschmannNIIR EF K B0


8

117

65 4

1

3

29

10

Fig. 7-14 Dimension diagram of circular, 12-pin connector




Service

8.1 Areas of responsibility of Siemens and Bosch

The areas of responsibility with respect to Sales and Servicing as shown inTable 8-1 below have been agreed between Siemens and Bosch.

Table 8-1 Areas of responsibility for sales and servicing

Siemens AG Robert Bosch GmbH

“Electrical” equipment/configuring

“Hydraulic” equipment/configuring

HMI/MMC Valves

NC/PLC Hydraulic equipment

NE (mains supply equipment) Power units

Closed-loop control modules Cylinders

Power sections Pipework

Motors Pressure sensors

Cabling Encoder sensors

Hydraulic drive module

Hydr. system cabling (see Sect. 7.3.2)

Note

Neither company bears sole responsibility for the overall installation.

Siemens AG and Robert Bosch GmbH are deemed to bear responsibility only ifthey are the system supplier of the components listed in Table 8-1 or have certi-fied explicit system compatibility for components supplied by other manufactur-ers.

8

02.99



8.2 Hotline

Hotline

Tel. No. ++49–(0)9131/98–3471 (FDD) and –3475 (MSD)

Fax. ++49–(0)9131/98–1313

Mon–Fri 8.00 am – 5.00 pm

Emergency service

Tel. No. 0172 840 8776

Mon–Fri 5.00 – 10.00 pm

Sat 8.00 am – 10.00 pm

Christmas Eve 8.00 am – 2.00 pm

New Year’s Eve 8.00 am – 2.00 pm

Sun None

Hotline

Tel. No. ++49–(0)711/811–24806

Fax. ++49–(0)711/811–1424

Mr. Laube AT/VKS2–Si

Mail [email protected]

Mon–Fri 7.30 am – 5.00 pm

Siemens AG

Robert BoschGmbH

8 Service

8.2 Hotline

A-233 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Hydraulics

A.1 Servo solenoid valves

A.1.1 General

The servo solenoid valve is the final control element in the electro-hydrauliccontrol loop. It converts electrical quantity U=–10...+10 V into hydraulic quanti-ties pressure p and flow Q, and thus into a cylinder movement.

These valves are of the sliding-spool type. A valve spool with 4 control edgesmoves inside a steel sleeve on which the control bore is connected to the 4ports in the valve housing.

The ports in the valve housing are:

P: Pressure port (inlet)

T: Tank port (return)

A and B: Working ports (cylinder)

The valve spool slides steplessly through 3 switching positions (continuousvalve).

A B

T P

Housing

Steel sleeve

Valve spool

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎ

ÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

Fig. A-1 Sliding spool principle

Spool principle

A

02.99

A-234 Siemens AG 2000. All rights reserved


On the standard servo solenoid valves of sizes 6 and 10, the valve spool is actuated directly by a stepless actuating solenoid. This converts a cur-rent I into a force F, which is compared with the force of the reset spring. Thiscomparison of forces finally produces a travel s, and thus an opening cross-sec-tion on the control edges of the valve spool.

In order to compensate for disturbance forces acting on the valve spool (flowforces) and to reduce the hysteresis and response sensitivity or range of inver-sion, the position of the armature, and therefore the spool travel, is scanned andapplied to a position control loop as an actual value. Deviations from the spoolposition setpoint are correctly continuously in this way. This method is particu-larly successful in reducing the valve sensitivity to dirt.

Very small control deviations, such as those caused when the valve spool“sticks”, can be corrected through mobilization of the total available magneticforce.

A wear-resistant, proximity-type differential transformer (LVDT) is employed asthe spool travel sensor.

Valve amplifier

Valve spoolFF FM

UE

ÉÉÉÉÉÉ

Reset spring Actuatingsolenoid

Positionsensor

SU

F

FF

FM

S

Fig. A-2 Solenoid actuation with position control of valve spool

The operating principle of the servo solenoid valve is represented by a symbolin the hydraulic circuit diagram. The symbol comprises a series of differentsquares denoting the valve positions.

The three stepless-transition valve positions are represented by additional lines.The symbol also indicates the relevant mode of actuation, in the example below,direct solenoid actuation with spring return at one end.

In the de-energized state, the valve assumes a 4th fail-safe position. Two alter-native fail-safe positions are available.

Solenoid actuationwith position control of valvespool

Graphic symbol

A Hydraulics


02.99


The symbol also reveals the principle of position control applied to the valvespool.

Reset spring

A B

P T

Actuating solenoid

Position sensor

Valve amplifier withposition control

SetpointUE=0...10V

A B

P T

A B

P T

Fail-safe disabled Fail-safe enabled

Fig. A-3 Graphic symbol

A Hydraulics


02.99



Zero overlap by a continuous valve around its mid-position is an important req-uisite for its application in a position control loop.

A positive overlap has a disturbing effect because of the final control element“dead zone”.

In contrast, a negative overlap results in a marked increase in oil leakage.

In order to achieve zero overlap, valve spools, spool housings and spoolsleeves must be manufactured with extreme precision and made of wear-resist-ant materials. The production costs incurred are correspondingly high.

To maintain the zero overlap over prolonged operating periods, it is essential toensure that a clean pressure medium is used (to prevent erosion of controledges).

ÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎÎ

ÎÎÎÎ

A

T T

B

Ü = –P

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎÎÎ

ÎÎ

A

T T

B

Ü = +P

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎÎÎ

ÎÎÎÎÎÎ

ÎÎ

ÎÎÎÎ

A

T T

B

Ü = 0P

+Q

–Q

–UE +UE

+Q

–Q

–UE +UE

+Q

–Q

–UE +UE

Fig. A-4 Zero overlap in mid-position

The quality of zero overlap in the mid-position is represented by the so-calledpressure intensification characteristic.

This states what percentage of the setpoint signal is needed to achieve a pres-sure difference corresponding to 80 % system pressure at the closed load ports.The values of this characteristic are typically in the 1...3 % range.

The following graphic representation of the measurement, which acquires all 4control edges, provides precise information.

8060

4020

2040

6080

p [% of pPU]

–UE[%] +UE [%]1 2 33 2 1

Dp

PA PB

PPU

BA

P

Fig. A-5 Pressure amplification

Zero overlap inmid-position

Pressure intensification

A Hydraulics


02.99


The stepless slide movement, and thus the change in the throttle cross-sectionat the control edges, results in a corresponding flow which is represented as afunction of spool travel s or of electrical input signal U (manipulated variable).

The linearity is determined by the geometry of the control edges of the spoolsleeve.

The flow is not only dependent on the opening cross-section, but also on thepressure drop in accordance with the law of flow:

Q p

auch vom Druckabfall abhängig.

A B

P T

P B toA T

P A toB T

Flow Q

Spool travel sInput signal I

pNOM per controledge = 35 bar

pPA pBTA B

P T

Fig. A-6 Flow characteristic

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Q

UE

Window in spool sleeve

Spool stroke

Fig. A-7 Control edge on spool sleeve

Flow characteristic, linear

A Hydraulics


02.99



In addition to valves with a linear characteristic, values with a knee-shapedcharacteristic are used in many cases to increase the finer resolution in thepositioning range to better control the effects of static/sliding friction. These areachieved by means of corresponding windows (control edges) in the steel valvesleeve. A constant machining velocity of the drive directly at the knee-point ofthe valve is not recommended.Definition for the position of the knee-point, e.g. 40% knee.Up to 40 % of the spool value or setpoint signal, only 10 % of the maximumopening cross-section (flow) is released.

40%

10%

+Q

–Q

–UE +UE

Rapid traverse

Machining velocity

Fig. A-8 Definition of flow characteristic

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

Q

UE

Spool stroke

40 % UE

10 %

Qm

ax

Fig. A-9 Valve with knee-shaped characteristic

The knee-shaped characteristic of the valve is linearized in the HLA module tomatch it to the closed-loop control of the overall drive (cylinder). No steady-stateoperating point should be defined in the knee-point area.The corresponding valve data are stored in the HLA module and automaticallyparameterized when the order number is entered.

+Q

–Q

–UE +UE

Valve characteristic

Linearized characteristic

Compensation

10%

40%

Fig. A-10 Linearization of knee-shaped characteristic

Flow characteristic,knee-shaped

Linearization ofknee-shaped characteristic

A Hydraulics


02.99


This describes the maximum flowrate with fully opened valve in relation to apressure drop of ∆p=35 bar per control edge.

Typical values are:

Size 6: Q=4...40 l/min

Size 10: Q=50...100 l/min

With pilot-controlled valves, the rated flowrate is related to ∆p=5 bar per controledge. (Reduction in losses with higher flow rates.)

The values for sizes 10 and 16 are then as follows:

Size 10: Q=55...85 l/min

Size 16: Q=120...200 l/min

The flow under other pressure conditions is calculated according to the law offlow by the following formula:

∆pXQX=Qnom ∆pnom

The speed of the cylinder is determined by a combined throttling effect at theinlet and outlet. The cylinder is clamped hydraulically at both ends.

In order to ensure adequate effectiveness of the outlet throttle on cylinders withsingle-ended piston rod and draw load, larger servo solenoid valves with asym-metrical characteristics are available as alternatives.

+Q

–Q

–UE +UE

PA

PB

QA

QB

v

A B

P T

G

Fig. A-11 Asymmetrical characteristics

The dynamic response characteristics indicate how fast the valve can react tosetpoint changes.

One characteristic that is indicative of dynamic response is the actuating time.This defines how much time the valve spool needs to open the valve in re-sponse to a step change in the input signal from 0 V to 10 V.

Rated flowrate

Asymmetricalcharacteristics

Dynamic response

A Hydraulics


02.99



More exact information about the dynamic response is provided by the Bodediagram or frequency response. In this case, a sinusoidal setpoint is applied tothe valve. The frequency up to which the actual value (valve spool) can followthe setpoint is then noted. The amplitude and phase displacement must beplotted logarithmically as a function of frequency.

AE

–180

–160

–140

–120

–100

–80

–60

–40

–20

–010 20 40 60 80100 200 300 f [Hz]

at –905

at –3 dB

j [5]

0

–2

–4

–6

–8

–10

2

[dB]

5 %

100

Signal 100 Umax

Signal 5% Umax

Fig. A-12 Dynamic response of valve

In order to achieve the longest possible control edge life, thus assuring the qual-ity of the zero overlap, a certain degree of purity of the hydraulic medium (fluid)must be maintained.

The objective is contamination class 7...9 to NAS 1638, this can normally beachieved with a pressure filter β10=75.

Filtration grade

A Hydraulics


02.99


These three terms express similar characteristics.

The term “Hysteresis” refers to the greatest difference in the input signal foridentical outputs signals on traversal of a full signal range.

On a servo solenoid valve, the hysteresis is caused by

mechanical friction,

magnetic hysteresis of electromagnetic signal transducer and

the play between transmission elements.

The position control corrects the hysteresis.

The hysteresis on Bosch closed-loop proportional values is less than 0.2 % andis compensated for in the closed control loop.

The terms “Response sensitivity” and “Range of inversion” refer to the signallevel required to set a valve in motion again after it has stopped. The values ofthese characteristics correspond to about half the hysteresis.

To overcome residual hysteresis or initial valve friction, a friction compensationfunction can be activated in the HLA module.

Q

U

Hysteresis

Q

U

Q

U

Response sensitivity

Range of inversion

Fig. A-13 Hysteresis, response sensitivity and range of inversion of servo solenoid valve

Hysteresis, response sensitivity, rangeof inversion

A Hydraulics


02.99



A.1.2 Servo solenoid valves of sizes 6 and 10

The standard series of size 6 and 10 servo solenoid valves shown in the follow-ing diagram are designed according to the same principle.

The valve spool in its steel sleeve is pushed in contact with the reset spring bythe actuating solenoid. The armature axis of the solenoid is mechanicallycoupled to the ferrite core of the position sensor integrated in the solenoid.

This sensor is a proximity-type, wear-resistant differential transformer ( LVDT).

The housing of the integrated valve amplifier (On Board Electronic OBE) isbolted directly onto the solenoid/position sensor module.

Electrical power is supplied and the setpoint injected via a 7-pin connector.

If the valve is operating around the mid-position, the solenoid is energized byabout 50%. When the supply voltage is disconnected, the valve assumes a 4thposition, i.e. the “fail-safe position”. On connection and disconnection of thesupply, it slides through the crossed position.

The valves are available with a variety of rated flows and two different fail-safepositions.

7-pin connector Valve amplifier

Valve spool

Steel sleeve Actuating solenoid coil

Reset spring Actuating solenoid armature

LVDT coils

LVDT ferrite core

Size 6 Size 10

A B

P T

A B

P T

Fail-safe disabled

Fail-safe enabled

Fig. A-14 Sizes 6 and 10 servo solenoid valves, directly actuated

Mechanicalconstruction

A Hydraulics


02.99


The functions of the integrated valve amplifier are implemented with analogelectronics and illustrated in a block diagram (see Fig. A-15).

The main amplifier functions are:

Supply and evaluation of the position sensor (AC/DC converter)

Comparison of setpoint input signal with spool actual value

Formation of manipulated variable via a PID controller for the output stage

Timing output stage with pulse length modulation

The amplifier is calibrated to match the valve at the factory. A zero-point adjust-ment is made via the NC during start-up.

+24 V=

Reference point

Setpoint 0...

Actual value spool

Supply

Protective earth

Screening

2.5 AF

+–10 V

0 V

Actual value spool0 V

Sign.

+15V–15 V

100k

100k10k

+U B

DCDC

S

U

PID

Logic

+

–

ABCDEF

+UB

value

value

Fig. A-15 Block diagram of sizes 6 and 10 directly actuated servo solenoid valves

Valve amplifier

A Hydraulics


02.99



A.1.3 Pilot-actuated sizes 10 and 16 servo solenoid valves

In order to control higher flow rates, the principle of pilot control has been ap-plied.

A directional servo solenoid valve of size 10 or 16 with corresponding controledges on the valve spool functions as the main stage. Like the piston rod of acylinder, this stage is hydraulically clamped and positioned by a size 6 pilotvalve (see Section A.1.2).

The position of the main spool is scanned by another position sensor and thecorresponding actual value applied to a second, subordinate position controlloop.

The control fluid can be inlet and outlet either internally via ports P and T or, asoften the case in practice, externally via additional ports x and y. Plugs are usedto convert the assembly to the desired method.

Pilot-actuated servo solenoid valves have only the three stepless-transitionpositions.

They do not have the 4th fail-safe position. If the supply voltage is discon-nected, the spring force of the main spool causes the valve to assume an indif-ferent mid-position.

The integrated valve amplifier is mounted on the pilot valve assembly and con-tains both position control loops. A cable is used to connect the position sensoron the main stage to the amplifier.

Mechanicalconstruction

Inlet and outlet ofhydraulic fluid

Positions

Valve amplifier

A Hydraulics


02.99


Graphic symbol in detailed form

Graphic symbol in simplified form

Fig. A-16 Pilot-actuated sizes 10 and 16 servo solenoid valves

A Hydraulics


02.99



+15

V–1

5 V

Ref

eren

ce p

oint

Set

poin

t 0...

Act

ual v

alue

spo

ol

Sup

ply

Pro

tect

ive

eart

h

Scr

eeni

ng

2.5

AF

100k

100k

10k

+U

B

DC D

C

S

U

PID

Logi

c

+ –P

D+ –

0...

1 2 3 4

+ –10

V

+ –10

V

+24

V=

A B C D E F

0 V

1)A

ctua

l val

ue s

pool

0 V

Sig

n.

1) D

o no

t con

nect

to 0

Vsu

pply

+U

B

–15

V=

ref.

0+

15 V

=S

igna

l

Mai

nst

age

Pilo

tst

age

Diff

.am

p.

S

U

valu

e

valu

e

Fig. A-17 Block diagram of pilot-actuated sizes 10 and 16 servo solenoid valves

A Hydraulics


02.99


A.1.4 HRV valves

HRV (High Response Valve) is a series of servo solenoid valves with excellentdynamic and static characteristics and therefore extends the product range tocover particularly demanding applications.

The core of the series is the size 6 valve (HRV 1), which is also usedas a pilot valve for the size 10...size 25 (HRV 2) series.

Both valve stages on pilot-actuated valves operate under position control.

In comparison to other valves, the HRV series has the following features:

Significantly better dynamic response

More compact dimensions

A higher hydraulic switching capacity.

The HRV valve comprises the following components:

Flow-force-compensated hydraulic section with wear-resistant steel sleeveand spring centered control spool,

Double-stroke solenoid with inductive position encoder (LVDT) and

Integrated electronics (OBE).

High-response valves do not have the fail-safe position provided on other servosolenoid valves. Many applications therefore require external non-return valves,such as those available as sandwich-plate valves.

Graphic symbol in simplified form

Valve spoolSteel sleeve

12-pin connector

Valve amplifier

Position encoderDouble-stroke solenoid

A B

P T

Fig. A-18 High-response valves

General

Features

A Hydraulics


02.99



+24

V=

1 2 3 4 5 6

0 V

7 8 9 10 11

24 V

24 V

24 V

0 V

Sig

n.

0 V

+15

V–1

5 V

Out

put s

tage

sup

ply

Ena

ble

sign

al

Set

poin

t 0...

Act

ual v

alue

spo

ol v

alue

Ena

ble

ackn

owle

dgem

ent

Ele

ctro

nics

sup

ply

Err

or m

essa

ge

Pro

tect

ive

eart

h

Scr

eeni

ng

+24

V=/

<=0.

5 A

2.5

AF

100k

100k

10k

+U

B

DC D

C

+U

B

SU

HR

V

PID

Logi

c

+ –P

D+ –

0...

1 2 3 4

+U

B

+ –10

V

+ –10

V

Fig. A-19 Block diagram of HRV valves

A Hydraulics


02.99


A.2 Cylinder

The cylinder acts as the drive element in the electrohydraulic control loop.

It converts the flow to a linear movement. In this case, high velocities are re-quired for rapid traverse movements as well as slow velocities for machiningoperations

On a through-rod cylinder, a piston rod of the same diameter is mounted at bothends as a power transmission element. Consequently, the piston areas at the Aand B ends are identical. Likewise, at a constant piston speed, the incomingflow is equal to the displaced flow in the settled state. The piston rods on thethrough-rod cylinder thus travel in and out symmetrically.

In contrast to the through-rod cylinder, a differential cylinder has either a power-transmission piston rod at one end only or the piston rods at its two ends havedifferent diameters. In the latter case, the piston areas at the A and B ends aredifferent. Furthermore, at a constant piston speed, the displaced flow is not thesame as the incoming flow. The maximum piston travel-in and travel-out speedsare not the same on a differential cylinder (see Section 4.7).

This asymmetry can, however, be compensated by means of the piston areaadaptation function (MD 5112: VALVE_FLOW_FACTOR_A_B).

Apart from the piston diameter, it is necessary to specify the rod diameters atthe A and B ends. On a differential cylinder, both rod diameters are different,one of the rods might even have a zero diameter. The maximum piston strokeand cylinder dead volume are also required.

Differential cylinderD0 D1

A B

Through-rod cylinderD2 D0 D1

A B

D1=D2

D2 D0 D1

A B

D1D2

Fig. A-20 Cylinder principle

General

Through-rod ordifferential cylinder

A Hydraulics

A.2 Cylinder

02.99



In order to ensure the lowest possible frictional forces, the quality of the sealsand guides on the piston, and the piston rod itself, must be particularly high.

Transitions from static to sliding friction have a particularly adverse affect on thequality of control accuracy. A friction compensation setting has been provided inthe HLA module (MD 5460: FRICTION_COMP_RADIENT) for the purpose ofcounteracting initial friction.

ÌÌÌÌ

ÌÌÌÌ

ÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ

ÌÌÌÌÌÌÌÌÌÌÌÌ

ÌÌÌÌ

ÌÌÌ

ÌÌÌÌÌÌÌÌÌÌÌÌ

ÌÌÌÌÌÌ

ÌÌ

ÌÌÌÌ

Piston

Piston rod

2 x guide ring(PTFE)

Seal(FPM+PTFE)

2 x guide ring(PTFE)

Stabilizing ring(FPM)

2 x sealing ring(FPM+PTFE)

Fig. A-21 Cylinders

The dead volume is the volume between the cylinder and servo solenoid valvethat is not displaced by one piston stroke. It reduces the natural frequency ofthe drive and should be avoided wherever possible.

Cylinder pipework should be kept as short as possible, i.e. the servo solenoidvalve should be mounted directly on the cylinder.

The dead volume is parameterized in the HLA module (MD 5135, MD 5136 andMD 5141...5143).

Quality of seals

Dead volume

A Hydraulics

A.2 Cylinder

B-251 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Abbreviations

Working port on cylinder

Analog drive

Asynchronous rotation motor (main spindle drive)

Automation System

Advanced Technology

Working port on cylinder

Proximity limit switch

Communication Module

Digital/analog converter channel

Digital to Analog

Distributed Peripherals (I/Os)

Driver Module

Dynamic Stiffness Control

Electromagnetic Compatibility

Modules/components endangered by electrostatic discharge

End User Interfaces

Feed Drive

Fast Fourier Transform

Enabling voltage internal ground

Enabling voltage internal +24 V

Hard Disk

Handheld Unit

Hydraulic Linear Drive

High Response Valve

Hydraulic Drive

Infeed/Regenerative Feedback Module

Interface Module (SIMATIC S7-300)

Interface Module Address

Industry Standard Architecture

Communication Bus

Light Emitting Diode

A

ANA

ARM (MSD)

AS

AT

B

BERO

COM

DAC

D/A

DP

DRV

DSC

EMC

ESD

EUS

FDD

FFT

FRM

FRP

HD

HHU

HLA

HRV

HYD

I/RF

IM

IM Address

ISA

K Bus

LED

B

02.99

B-252 Siemens AG 2000. All rights reserved


Linear Variable Differential Transducer

External 0 V input

Machine Control Panel

Machine Data

Machine-readable product designation (Order No.)

Man Machine Communication

MultiPoint Interface

Main Spindle Drive

Numerical Control

Numeric Control Unit

Mains Infeed (module)

Non-Maskable Interrupt

On-Board Electronics

Operator Panel

Operator Panel Interface

Pressure port (inlet), servo solenoid valve

External +24 V input

Parameter Basic List

I/O Bus

Position Control Loop

Personal Computer Memory Card International Association

I/O Module

Programming Unit

Program Invocation

Controller with Proportional, Integral and Differential components

Programmable Logic Controller

Power Supply (SIMATIC S7-300)

Control loop

Serial Communication Control

Synchronous Linear Motor

Signal Module of SIMATIC S7-300, e.g. I/O modules

Synchronous Rotation Motor (feed drive)

Software

Tank port (return), servo solenoid valve

Terminal

Unregulated incoming supply

LVDT

M24EXTIN

MCP

MD

MLFB

MMC

MPI

MSD

NC

NCU

NE

NMI

OBE

OP

OPI

P

P24EXTIN

PBL

P Bus

PCL

PCMCIA

PER

PG

PI

PID

PLC

PS

RK

SCI

SLM

SM

SRM (FDD)

SW

T

Term.

UE

B Abbreviations

02.99

B-253 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Monitoring

Velocity Control Loop

Video Graphics Adapter

Status class

ÜW

VCL

VGA

ZK

B Abbreviations

02.99

B-254 Siemens AG 2000. All rights reserved


B Abbreviations

Notes

C-255 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Definition of Terms

Cylinder piston surface

Cylinder piston diameter

Cylinder piston rod diameter

Natural frequency (resonant frequency) of hydraulic drive

Limit frequency that can be achieved by velocity-controlled drive

Natural frequency of servo solenoid valve

Limit frequency of servo solenoid valve

Cylinder stroke

Stroke at which min. natural frequency occurs

Mass on piston rod

Pressure at A end of cylinder

Pressure at B end of cylinder

Pump pressure

Pressure difference (rated pressure drop)

Pressure drop in the feed pipe

A

D1, D2

d1, d2

f0drive

f0control

f0valve

fv

h

hx

m

pA

pB

pp

∆p

∆pPA

C

02.99

C-256 Siemens AG 2000. All rights reserved


Pressure drop in the discharge pipe

Rated flow of servo solenoid valve

Servo solenoid valve flow

Valve setpoint

Velocity setpoint

Actual velocity

Position setpoint

Actual position

Valve spool position

∆pBT

Qnom

Qvalve

Uset valve

vset

vact

xset

xact

xvalve

C Definition of Terms

D-257 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

References

D.1 Electrical applications

General Documentation

SINUMERIK 840D/810D/FM-NCOrdering Information Catalog NC 60.1Order No.: E86060-K4460-A101-A6-7600

SIMATICSIMATIC S7 Programmable Logic Controllers Catalog ST 70Order No.: E86 060-K4670-A111-A3

SINUMERIK 840D/810D/FM-NCTechnical InformationCatalog NC 60.2Order No.: E86060-D4460-A201-A4-7600

SINUMERIK 840D/810D/FM-NCBrochure

SINUMERIK, SIROTEC, SIMODRIVEAccessories and Equipment for Special-Purpose MachinesCatalog NC ZOrder No.: E86060-K4490-A001-A6-7600

Electronic Documentation

The SINUMERIK System (04.00 Edition)DOC ON CD (includes all SINUMERIK 840D/810D/FM-NC and SIMODRIVE 611D publications)Order No.: 6FC5 298-5CA00-0BG2

/BU/

/ST7/

/VS/

/W/

/Z/

/CD6/

D

02.99

D-258 Siemens AG 2000. All rights reserved


User Documentation

SINUMERIK 840D/810D/FM-NCAutoTurn Graphic Programming System (07.99 Edition)Operator’s GuidePart 2: SetupOrder No.: 6FC5 298-4AA50-0BP2

SINUMERIK 840D/810D/FM-NCShort Guide AutoTurn Operation (07.99 Edition)Order No.: 6FC5 298-4AA30-0BP2

SINUMERIK 840D/810D/FM-NCAutoTurn Graphic Programming System (07.99 Edition)Operator’s GuidePart 1: ProgrammingOrder No.: 6FC5 298-4AA40-0BP2

SINUMERIK 840D/810D/FM-NCOperator’s Guide (04.00 Edition)Order No.: 6FC5 298-5AA00-0BP2

– Operator’s Guide

– Operator’s Guide Interactive Programming (MMC 102/103)

SINUMERIK 840D/810D/ FM-NCOperator’s Guide Unit Operator Panel (04.96 Edition)Order No.: 6FC5 298-3AA60-0BP1

SINUMERIK 840D/810DOperator’s Guide HT6 (HPU new) (06.00 Edition)Order No.: 6FC5 298-0AD60-0BP0

SINUMERIK 840D/810D/FM-NCShort Operation Guide (12.98 Edition)Order No.: 6FC5 298-5AA10-0BP0

SINUMERIK 840D/810DOperator’s Guide ManualTurn (12.99 Edition)Order No.: 6FC5 298-5AD00-0BP0

SINUMERIK 840D/810DShort Guide ManualTurn (11.98 Edition)Order No.: 6FC5 298-2AD40-0BP0

SINUMERIK 840D/810DOperator’s Guide ShopMill (11.99 Edition)Order No.: 6FC5 298-5AD10-0BP1

SINUMERIK 840D/810DShort Guide ShopMill (01.98 Edition)Order No.: 6FC5 298-2AD30-0BP0

/AUE/

/AUK/

/AUP/

/BA/

/BAE/

/BAH/

/BAK/

/BAM/

/KAM/

/BAS/

/KAS/

D References 04.00

02.99


SINUMERIK 840D/840Di/810DOperator’s Guide Handheld Programming Unit (04.00 Edition)Order No.: 6FC5 298-5AD20-0BP1

SINUMERIK 840D/840Di/810D/FM-NCUser’s Guide Measuring Cycles (04.00 Edition)Order No.: 6FC5 298-5AA70-0BP2

SINUMERIK 840D/840Di/810D/FM-NCDiagnostics Guide (04.00 Edition)Order No.: 6FC5 298-5AA20-0BP2

SINUMERIK 840D/840Di/810D/FM-NCProgramming Guide Fundamentals (04.00 Edition)Order No.: 6FC5 298-5AB00-0BP2

SINUMERIK 840D/840Di/810D/FM-NCProgramming Guide Advanced (04.00 Edition)Order No.: 6FC5 298-5AB10-0BP2

SINUMERIK 840D/810D/FM-NCShort Guide Programming (12.98 Edition)Order No.: 6FC5 298-5AB30-0BP0

SINUMERIK 840D/840Di/810D/FM-NCProgramming Guide Cycles (04.00 Edition)Order No.: 6FC5 298-5AB40-0BP2

PCIN 4.4Software for Data Transfer to/from MMC ModuleOrder No.: 6FX2 060 4AA00-4XB0 (German, English, French)Order from: WK Fürth

SINUMERIK 840DiSystem Overview (06.00 Edition)Order No.: 6FC5 298-5AE40-0BP0


SINUMERIK 840D/840Di/810D/FM-NCSIMODRIVE 611DLists (04.00 Edition)Order No.: 6FC5 297-5AB70-0BP2

SINUMERIK 840D/840Di/810D/FM-NCOperator Components Manual (HW) (04.00 Edition)Order No.: 6FC5 297-5AA50-0BP2

/BAP/

/BNM/

/DA/

/PG/

/PGA/

/PGK/

/PGZ/

/PI/

/SYI/

a) Lists

/LIS/

b) Hardware

/BH/

D References04.00

02.99



SIMODRIVE SensorAbsolute Encoder with Profibus DPUser Guide (HW) (02.99 Edition)Order No.: 6SN1197-0AB10-0BP1

SINUMERIK, SIROTEC, SIMODRIVEEMC Installation GuidePlanning Guide (HW) (06.99 Edition)Order No.: 6FC5 297-0AD30-0BP1

SINUMERIK 810DManual Configuring (HW) (04.00 Edition)Order No.: 6FC5 297-3AD10-0BP2

SINUMERIK 840DNCU 561.2–573.2 Configuring Manual (HW) (04.00 Edition)Order No.: 6FC5 297-5AC10-0BP2

SINUMERIK FM-NCNCU 570 Configuring Manual (HW) (04.96 Edition)Order No.: 6FC5 297-3AC00-0BP0

SIMODRIVE Sensor (05.99 Edition)Measuring System for Main Spindle DrivesConfiguring/Installation Guide, SIMAG-H (HW)Order No.: 6SN1197-0AB30-0BP0

SINUMERIK 840D/840Di/810D/FM-NCDescription of Functions, Basic Machine (Part 1) (04.00 Edition) (the various sections are listed below)Order No.: 6FC5 297-5AC20-0BP2

A2 Various Interface SignalsA3 Axis Monitoring, Protection ZonesB1 Continuous Path Mode, Exact Stop and Look AheadB2 AccelerationD1 Diagnostic ToolsD2 Interactive ProgrammingF1 Travel to Fixed StopG2 Velocities, Setpoint/Actual-Value Systems, Closed-Loop ControlH2 Output of Auxiliary Functions to PLCK1 Mode Group, Channel, Program Operation ModeK2 Axes, Coordinate Systems, Frames,

Actual-Value System for Workpiece, External Zero OffsetK4 CommunicationN2 EMERGENCY STOPP1 Transverse AxesP3 Basic PLC ProgramR1 Reference Point ApproachS1 SpindlesV1 FeedsW1 Tool Compensation

/BHA/

/EMV/

/PHC/

/PHD/

/PHF/

/PMH/

c) Software

/FB1/

D References 04.00

02.99


SINUMERIK 840D/840Di/810D(CCU2)/FM-NCDescription of Functions, Extended Functions (Part 2) (04.00 Edition) including FM-NC: Turning, Stepper Motor(the various sections are listed below)Order No.: 6FC5 297-5AC30-0BP2

A4 Digital and Analog NCK I/OsB3 Several Operator Panels and NCUsB4 Operation via PG/PCF3 Remote DiagnosticsH1 Jog with/without HandwheelK3 CompensationsK5 Mode Groups, Channels, Axis Replacement L1 FM-NC Local BusM1 Kinematic TransformationM5 MeasurementN3 Software Cams, Position Switching SignalsN4 Punching and NibblingP2 Positioning AxesP5 OscillationR2 Rotary AxesS3 Synchronous SpindlesS5 Synchronized Actions (up to and including SW 3)S6 Stepper Motor ControlS7 Memory ConfigurationT1 Indexing AxesW3 Tool ChangeW4 Grinding

SINUMERIK 840D/840Di/810D(CCU2)/FM-NCDescription of Functions, Special Functions (Part 3) (04.00 Edition) (the various sections are listed below)Order No.: 6FC5 297-5AC80-0BP2

F2 3-Axis to 5-Axis TransformationG1 Gantry AxesG3 Cycle TimesK6 Contour Tunnel MonitoringM3 Coupled Motion and Leading Value CouplingS8 Constant Workpiece Speed for Centerless GrindingT3 Tangential ControlV2 PreprocessingW5 3D Tool Radius CompensationTE1 Clearance ControlTE2 Analog AxisTE3 Master-Slave for DrivesTE4 Transformation Package HandlingTE5 Setpoint ExchangeTE6 MCS Coupling

SIMODRIVE 611D/SINUMERIK 840D/810DDescription of Functions, Drive Functions (04.00 Edition)(the various sections are listed below)Order No.: 6SN1 197-0AA80-0BP6

DB1 Operational Messages/Alarm ReactionsDD1 Diagnostic FunctionsDD2 Speed Control LoopDE1 Extended Drive Functions

/FB2/

/FB3/

/FBA/

D References04.00

02.99



DF1 Enable CommandsDG1 Encoder ParameterizationDM1 Calculation of Motor/Power Section Parameters and

Controller DataDS1 Current Control LoopDÜ1 Monitors/Limitations

SINUMERIK 840D/SIMODRIVE 611D DigitalDescription of FunctionsANA Module (11.99 Edition)Order No.: 6SN1 197-0AB80-0BP0

SINUMERIK 840DDescription of Functions Digitizing (07.99 Edition)Order No.: 6FC5 297-4AC50-0BP0

DI1 Start-upDI2 Scanning with Tactile Sensors (scancad scan)DI3 Scanning with Lasers (scancad laser)DI4 Milling Program Generation (scancad mill)

CAM Integration DNC NT-2000Description of Functions System for NC Data Management and Data Distribution (10.99 Edition)Order No.: 6FC5 297-5AE50-0BP0

SINUMERIK 840D/810DDescription of Functions ISO Dialects for SINUMERIK (04.00 Edition)Order No.: 6FC5 297-5AE10-0BP1

SINUMERIK 840D/SIMODRIVE 611 digitalDescription of Functions HLA Module (08.99 Edition)Order No.: 6SN1 197-0AB60-0BP1

SINUMERIK 840D/810DDescription of Functions ManualTurn (12.99 Edition)Order No.: 6FC5 297-5AD50-0BP0

SINUMERIK 840D/810D/FM-NCDescription of Functions (03.96 Edition)Configuring of Operator Interface OP 030(the various sections are listed below)Order No.: 6FC5 297-3AC40-0BP0

BA Operator’s GuideEU Development Environment (Configuring Package)PS Online only: Configuring Syntax (Configuring Package)PSE Introduction to Configuring of Operator InterfaceIK Screen Kit: Software Update and Configuration

SINUMERIK 840DDescription of Functions C-PLC Programming (03.96 Edition)Order No.: 6FC5 297-3AB60-0BP0

/FBAN/

/FBD/

/FBDN/

/FBFA/

/FBHLA/

/FBMA/

/FBO/

/FBP/

D References 04.00

02.99


SINUMERIK 840D/810DDescription of Functions SINCOM Computer Link (02.00 Edition)Order No.: 6FC5 297-5AD60-0BP0

NFL Host Computer InterfaceNPL PLC/NCK Interface

SINUMERIK 840D/SIMODRIVEDescription of Functions SINUMERIK Safety Integrated (05.00 Edition)Order No.: 6FC5 297-5AB80-0BP1

SINUMERIK 840D/810DDescription of Functions ShopMill (05.00 Edition)Order No.: 6FC5 297-5AD80-0BP1

SIMATIC FM STEPDRIVE/SIMOSTEP (01.97 Edition)Description of FunctionsOrder No.: 6SN1 197-0AA70-0BP3

SINUMERIK 840D/810DDescription of Functions Synchronized Actions (04.00 Edition)for Wood, Glass, Ceramics, Presses Order No.: 6FC5 297-5AD40-0BP2

SINUMERIK 840D/810DDescription of FunctionsTool Information SINTDI with Online Help (04.99 Edition)Order No.: 6FC5 297-5AE00-0BP0

SIMODRIVE 611 universalDescription of Functions (10.99 Edition)Closed-Loop Control Component for Speed Control and PositioningOrder No.: 6SN1 197-0AB20-0BP2

SINUMERIK 840D/810DDescription of Functions Tool Management (04.00 Edition)Order No.: 6FC5 297-5AC60-0BP2

SINUMERIK 840DiManual (06.00 Edition)Order No.: 6FC5 297-5AE50-0BP0

SINUMERIK 840D/810D/FM-NCScreen Kit MMC 100/Unit Operator Panel (06.96 Edition)Description of Functions: Software Update and ConfigurationOrder No.: 6FC5 297-3EA10-0BP1

SIMODRIVE 611 universalShort Description (10.99 Edition)Closed-Loop Control Component for Speed ControlOrder No.: 6SN1 197-0AB40-0BP2

/FBR/

/FBSI/

/FBSP/

/FBST/

/FBSY/

/FBTD/

/FBU/

/FBW/

/HBI/

/IK/

/KBU/

D References04.00

02.99



SIMODRIVEPlanning Guide Linear Motors (02.00 Edition)(on request)ALL General Information about Linear Motors1FN1 1FN1 Three-Phase AC Linear Motor1FN3 1FN3 Three-Phase AC Linear MotorCON ConnectionsOrder No.: 6SN1 197-0AB70-0BP1

SIMODRIVEPlanning Guide Motors (01.98 Edition)Three-Phase AC Motors for Feed andMain Spindle DrivesOrder No.: 6SN1 197-0AA20-0BP3

SIMODRIVE 611-A/611-DPlanning Guide Inverters (08.98 Edition)Transistor PWM Inverters forAC Feed Drives and AC Main Spindle DrivesOrder No.: 6SN1 197-0AA00-0BP4

SIMODRIVE POSMO AUser Manual (02.00 Edition)Distributed Positioning Motor on PROFIBUS DPOrder No.: 6SN2 197-0AA00-0BP1

SIMODRIVE POSMO AInstallation Instructions (enclosed with POSMO A) (12.98 Edition)Order No.: 462 008 0815 00

SIMATIC S7-300 (10.98 Edition)– Manual: Assembly, CPU Data (HW)– Reference Manual: Module DataOrder No.: 6ES7 398-8AA03-8AA0

SIMATIC S7-300 (03.97 Edition)Manual: STEP 7, Basic Information, V3.1Order No.: 6ES7 810-4CA02-8AA0

SIMATIC S7-300 (03.97 Edition)ManualSTEP 7, Reference Manuals, V3.1Order No.: 6ES7 810-4CA02-8AR0

SIMATIC S7-300 (04.97 Edition)FM 353 Step Drive Positioning ModuleOrder in conjunction with Configuring Package

SIMATIC S7-300 (04.97 Edition)FM 354 Servo Drive Positioning ModuleOrder in conjunction with Configuring Package

/PJLM/

/PJM/

/PJU/

/POS1/

/POS2/

/S7H/

/S7HT/

/S7HR/

/S7S/

/S7L/

D References 04.00

02.99


SIMATIC S7-300 (10.99 Edition)FM 357 Multi-Axis Module for Servo and Stepper DrivesOrder in conjunction with Configuring Package

SIMODRIVE 611 (01.98 Edition)Manual Single-Axis Positioning for MCU 172AOrder No.: 6SN 1197-4MA00-0BP0

SIMODRIVE 611-A/611-D, SimoPro 3.1Program for Configuring Machine-Tool DrivesOrder No.: 6SC6 111-6PC00-0AAOrder from: WK Fürth

SIMODRIVE 611AInstallation and Start-Up Guide (04.00 Edition)Order No.: 6SN 1197-0AA60-0BP5

SINUMERIK 810DInstallation and Start-Up Guide (04.00 Edition)(incl. description of SIMODRIVE 611D start-up software)Order No.: 6FC5 297-3AD20-0BP2

SINUMERIK 840D/SIMODRIVE 611DInstallation and Start-Up Guide (04.00 Edition)(incl. description of SIMODRIVE 611D start-up software)Order No.: 6FC5 297-5AB10-0BP2

SINUMERIK FM-NCInstallation and Start-Up Guide (04.96 Edition)Order No.: 6FC5 297-3AB00-0BP0

SINUMERIK 840D/810DMMC Installation and Start-Up Guide (04.00 Edition)Order No.: 6FC5 297-5AE20-0BP2

IM1 Start-up functions for the MMC 100.2IM3 Start-up functions for the MMC 103IM4 Start-up functions for HMI Advanced (PCU 50)HE1 Editor helpBE1 Supplement operator interface

/S7M/

/SHM/

/SP/

d) Installation andstart-up

/IAA/

/IAC/

/IAD/

/IAF/

/IAM/

D References04.00

02.99



D.2 Hydraulic applications

Robert Bosch GmbH“Servo solenoid valves” catalog

Robert Bosch GmbH“Sensors and electronics” catalog

Robert Bosch GmbH“Electro-hydraulic proportional and control engineering” catalog

/AKY013/2/

/AKY013/4/

/USY013/3/

D References 04.00

E-267 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

EC Declaration of Conformity

Note

An extract from the EC Declaration of Conformity No. E002 V 25/02/99 isshown below. A complete copy of the EC Declaration of Conformity can befound in the “EMC Installation Guidelines” for the SINUMERIK, SIROTEC andSIMODRIVE controls.

E

02.99

E-268 Siemens AG 2000. All rights reserved


E EC Declaration of Conformity

02.99

E-269 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Appendix A to EC Declaration of Conformity No. E002 V 25/02/99

A16: Typical plant configuration SINUMERIK 840D/SIMODRIVE 611D with closed-loop hydraulics module (HLA)

All components which are designated in the Ordering Information as approved for operation in acombined SINUMERIK 840D / SIMODRIVE 611D installation comply with Directive 89/336/EECwhen operated in an installation of this type.

For compliance with standards, see Appendix C

Note:The plant configuration sketch illustrates only the basic measures to be implemented in a typical plantconfiguration to ensure compliance with Directive 89/336/EEC. In addition, especially in cases where the plant configuration deviates from this typical model, the installation guidelines for EMC plant design in the product documentation andthe EMC installation guidelines for SINUMERIK, SIROTEC and SIMODRIVE (order no.:6FC5297-0AD30-0BP0) must be noted and implemented.

Fil-ter

Mains terminal

Metal cabinet

Operator panel

Machinecontrol panel

840D611DwithHLD

Fil-ter

*)

**)

*) with I/RF module**)with UE module

Setpoint

Actual pressure

Actual position

Hydraulic valve control

Throttle

*)


02.99

E-270 Siemens AG 2000. All rights reserved


Appendix C to EC Declaration of Conformity No. E002 V 25/02/99

C: The compliance of the products with Council Directive 89/336/EEC has been verifiedthrough inspection and testing in accordance with the following product standard, basic technical specifications and the basic standards contained therein. Product categories SINUMERIK, SIROTEC, SIMODRIVE and SIMATIC are subject to the requirements of different standards.

C1 Product categories SINUMERIK*), SIMATIC, SIROTEC:

Basic specification: EN 50081-2 dated 8/93 1)

Basic standards: Subject of tests:EN 55011 2) Radio interference

Basic specification: EN 50082-2 dated 3/95 3)

Basic standards: Subject of tests:EN 61000-4-3 4) Radiated radio frequency field (amplitude-modulated)ENV 50204 5) Radiated radio frequency field (pulse-modulated)EN 61000-4-6 6) Conducted disturbancesEN 61000-4-8 7) Power frequency magnetic fieldsEN 61000-4-2 8) Electrostatic dischargeEN 61000-4-4 9) Electrical fast transient bursts

*) except for SINUMERIK 810D

C2 Product categories SIMODRIVE, SINUMERIK 810D:

Product standard: EN 61800-3 10)

C3 Other standards complied with:

1) VDE 0839 Part 81-2 6) IEC 801-6,VDE 0847 Part 4-6IEV 1000-4-6ENV 50141

2) VDE 0875 Part 11 7) VDE 0847 Part 4-8IEC 1000-4-8

3) VDE 0839 Part 82-2 8) VDE 0847 Part 4-2EN 60801 Part 2IEC 801-2VDE 0843 Part 2

4) VDE 0847 Part 4-3 9) VDE 0843 Part 4ENV 50140 VDE 0847 Part 4-4

IEC 801-45) VDE 0847 Part 204 10) VDE 0160 Part 100


Index-271 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Index

AAbbreviations of drive types, 3-53Acceleration feedback, 4-111Acceleration limitation, 4-106Achievable dynamic response, 4-97Activation of DAC output, 5-181Activation of data, 3-60Adaptation, 4-108Air pressure, 5-183Analogy of characteristic data, 1-17

BBlock diagram of control functions, 4-98

CCharacteristic compensation

Area adaptation, 4-125Friction, 4-107Linearization of valve, 4-126Offset, 4-129

Characteristics of servo solenoid valvesDynamic response, A-239Filtration grade, A-240Hysteresis, A-241Linearization of knee-shaped characteristic,

A-238Pressure intensification, A-236Range of inversion, A-241Rated flowrate, A-239Response sensitivity, A-241

Circularity test, 3-90Climatic environmental conditions, 5-183Closed-loop force control

Start-up, 4-116Static friction injection, 4-119

Closed-loop control functions, 4-100Closed-loop force control, 4-116

Configuration, 4-117Force controller, 4-120Force limitation, 4-116, 4-118Preconditions, 4-116

Closed-loop velocity controlAcceleration feedback, 4-111Adaptation of D component, 4-108Adaptation of P component, 4-108D component, 4-111I component, 4-110Integrator feedback, 4-110P component, 4-109Reference model, 4-112Velocity controller cycle, 4-107

Comparison of electrical and hydraulic drive sys-tems, 1-16

Configuring an OEM valve list, 3-94Example of an OEM valve list, 3-94Format, 3-94General, 3-94Language-dependent OEM texts, 3-96Language-dependent system texts, 3-96Language-dependent texts, 3-96

Configuring steps, 2-21Electrical, 2-21Hydraulic, 2-22

Configuring the hydraulic drive, 2-30Cylinder selection, 2-30Hydraulic power unit, 2-44Natural frequency, 2-42Selection of servo solenoid valve, 2-32Selection of shutoff valve, 2-39

Connection and power loss calculation for NCU,2-46

Connection configuration for HLA module, 2-27Connection of 24 V supply

With shutoff valve, D-146Without shutoff valve, D-146

Construction of an electro-hydraulically controlleddrive axis, 1-18

Control directionDetermine control direction, 3-64General, 3-64Limitation of manipulated voltage, 3-64

Control output, velocity controller, 4-113Controlled system gain|, 4-106Controller adaptation

General, 3-75Implementation, 3-75

Controller data/Calculate drive model data, 3-63

F

02.99

Index-272 Siemens AG 2000. All rights reserved


Controller optimization, 3-63D response, 3-73General, 3-70I response, 3-74P response, 3-73

CylinderConstruction, 1-19Dead volume, A-250Differential cylinder, A-249General, A-249Quality criteria, 1-19Quality of seals, A-250Through-rod cylinder, A-249

Cylinder data, 4-136Cylinder drive, Cylinder data, 4-136Cylinder selection, 3-58

Cylinder pipes, 2-31Friction, 2-31Mounting, 2-31Mounting position, 2-31Piston diameter, 2-30Position measuring system, 2-31Rod diameter, 2-30Seal, 2-31Stroke length, 2-30

DD component, 4-111DAC assignments, 5-180DAC parameterization, 3-91DAC selection list, 3-91DC supplies, 2-46Dew-point temperature td, 5-183Display options, 3-93Drive data

Dynamic model data, 4-139Mechanical drive components, 4-137Valve-to-drive connection, 4-137

Drive machine data, 3-54Drive model data, Changing valve data, 3-61Dust, harmful, 5-185Dynamic drive model data, 4-139Dynamic Stiffness Control (DSC), 4-115

EEarthing system, 2-49Error reactions, 6-187Examples of applications, 1-15

FFeasible dynamics, 2-43File functions

Loading data, 3-77Saving data, 3-77

Filter, Control output, velocity controller, 4-113Filters, Velocity setpoint filters, 4-101Fine adjustment and optimization, 3-64Force controller

Controlled system gain, 4-121D component, 4-122Feedforward control filter, 4-123Feedforward control gain, 4-120I component, 4-122P component, 4-121

Function generator, 3-86Position setpoint, 3-89Signal types, 3-86Signals, 3-86Start-up of force controller, 4-116Valve spool setpoint, 3-87Velocity setpoint, 3-88

HHydraulic drive unit, Drive power, 2-44Hydraulic power pack, Cooling, 2-44Hydraulic power unit, 1-20

Filtration, 2-44Flow, 2-44Pressure, 2-44Pump type, 2-44

II component, 4-110Integrator feedback, 4-110Interfaces

Firmware, 1-15Hardware, 1-15

LList selection of valve, 3-56Loaded valve data, 3-56

MMachine configuration, 3-51Machine data groups, 3-93Machine guideway

Friction, 1-18Guide mechanism, 1-18

Mains connection, 5-182Manipulated variable inversion, 4-132Manipulated voltage limitation, 4-132Measurement function

Measurement of position control loop, 3-84Measurement of velocity controller, 3-80

Measuring function, Valve control loop measure-ment, 3-79

Index 04.00

02.99

Index-273 Siemens AG 2000. All rights reservedSINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition

Measuring system, 5-176Measuring system data, 3-60

Absolute, 3-60Incremental, 3-60

Mechanical drive components, 4-137Mechanical environmental conditions, 5-183Message

SMRDY, D-149Valve spool is not responding, D-152Velocity controller at limit, D-151

Monitoring functions, D-150Measuring circuit, D-150Measuring circuit limit frequency reached,

D-151Power On alarms, D-150

Mounting the HLA closed-loop control plug-inmodule, 2-29

Mounting/supply dataConnection, 3-59Drive data, 3-59Supply unit, 3-59

NNatural frequency of the hydaulic drive, Feasible

dynamics, 2-43Natural frequency of the hydraulic drive, Servo

gain, 2-42NE module interfaces, 2-28

OObjective, 1-15Offset adjustment

Manipulated valve voltage offset, 3-67Offset of pressure sensors, 3-66Reference value for pressure sensors, 3-67

Options, 7-217Output of manipulated variables, 4-125Output voltage range of DAC outputs, 5-181Overview of functions, HLA firmware, 4-99Overview of HLA machine data, D-163Overview of start-up process for hydraulics mod-

ule, 3-51

PP component, 4-109Parameter set changeover, 4-99Pollutants, 5-185Position adjustment, 3-69

Position measuring system, 4-140Actual position, 4-142Description, 4-140Function, 1-20Minimum and maximum velocity, 4-140Phase error compensation, 4-140Position measuring system, linear scale grad-

uations|, 4-141Task, 1-19

Power disable, D-147, D-148Power enable, D-147Power supply

External, 2-46Internal, 2-46

Preset unlisted valve, 3-57Pressure sensors, D-143, 5-177

Offset adjustment, D-143Sensor adjustment, D-143

RReference model, 4-112References, D-257Referencing data for HLA

Adjustment of piston position, 3-69Piston neutral position, 3-69

Relative air humidity U, 5-183Requirements of external 26,5 V supply, 2-46

SSelection of servo solenoid valves

Asymmetrical characteristics, 2-35Characteristic, 2-34Connector pin assignments, 2-36Fail-safe position, 2-35HRV valves, 2-34Preferred range of servo solenoid valves, 2-36Servo solenoid valves, 2-34Valve size, 2-33Valve types, 2-32

Selection of shutoff valvesGeneral, 2-39Preferred range of shutoff valves, 2-41

Selection of valve, from list, 3-56Service functions

Diagnostic machine data, D-159Min/max display, D-157Monitor, D-158

Servo solenoid valveFunction, 1-19Task, 1-19

Index04.00

02.99

Index-274 Siemens AG 2000. All rights reserved


Servo solenoid valvesFeatures of HRV valves, A-247Flow characteristic linear, A-237Flow characteristic, knee-shaped, A-238Graphic symbol, A-234HRV valves, A-247Mechanical construction, A-242Pilot control principle, A-244Solenoid actuation with position control of

valve spool, A-234Spool principle, A-233Zero overlap in mid-position, A-236

Shipment conditions, 5-184Shock resistance, 5-183Shutoff valve, 1-19Start-up flow chart

Definition of drive travel direction, 3-65, 3-66Determine control direction, 3-65

Start-up sequence, 3-52Start-up support, Disabled softkeys, 3-78Static friction injection

Cutoff limit, 4-119Cylinder friction force, 4-120Velocity threshold, 4-119

Storage conditions, 5-184Supply unit data, 4-133System components, 2-26System overview

Components, 2-24Mounting the HLA closed-loop control plug-in

module, 2-29

TTerminals, D-144, 5-179

Error reactions, 6-187External 24 V supply, D-144Function switch, D-149ON/OFF sequence, D-144Power disable, D-147, D-148Power enable, D-147Setup mode, D-149Velocity controller disable, D-149Velocity controller enable, D-148

Travel directionCancel manipulated voltage limitation, 3-66Definition of drive travel direction, 3-65Definition of travel direction in NC, 3-66Determine control direction, 3-64Limitation of manipulated voltage, 3-64

UUnlisted valve data, 3-57User information, v

VValve amplifier, 1-19Valve data, 4-134Valve list

Example of an OEM valve list, 3-94Format, 3-94General, 3-94Language-dependent OEM texts, 3-96Language-dependent system texts, 3-96Language-dependent texts, 3-96

Valve selectionGeneral, 3-55Loaded valve data, 3-56Unlisted valve data, 3-57Valve selection softkey, 3-55

Velocity adjustment, Adjustment of controlled sys-tem gain, 3-68

Velocity compensation, Objective, 3-67Velocity control, Control output filter, 4-113Velocity controller, 4-107Velocity controller cycle, 4-107Velocity controller disable, D-149Velocity controller enable, D-148Velocity feedforward control, 4-100

Acceleration limitation, 4-106Controlled system gain|, 4-106Friction, 4-107Velocity feedforward control, 4-100Velocity setpoint filters, 4-101Velocity setpoint interpolation, 4-100Velocity setpoint limitation, 4-106

Velocity setpoint adaptation, 4-100Velocity setpoint filters, 4-101Velocity setpoint interpolation, 4-100Velocity setpoint limitation, 4-106Vibration resistance, 5-183

WWeighting factor, 2-46

XX101, 5-176X102, 5-176X111, 5-177X112, 5-177X121, 5-178X122, 5-178X141, 5-181X151, 5-181X341, 5-181X431, 5-179X432, 5-179

Index 04.00

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SINUMERIK 840DSIMODRIVE 611 digitalDescription of FunctionsHLA Module


Description of Functions

Order No.: 6SN1197–0AB60–0BP2Edition: 04.00

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SINUMERIK 840D SIMODRIVE 611 digital - Siemens AG · SINUMERIK 840D SIMODRIVE 611 digital Description of Functions 04.2000 Edition HLA Module Manufacturer/Service Documentation