FBHLA 1003 en PDF
FBHLA 1003 en PDF
FBHLA 1003 en PDF
sinumerik
& simodrive
HLA Module
SINUMERIK 840D
SIMODRIVE 611 digital
General 1
Configuration 2
Installation and Start-Up 3
Firmware Drive Functions 4
SINUMERIK 840D Hardware Drive Functions 5
SIMODRIVE 611 digital
Hydraulics Diagnostics 6
HLA module Peripherals/Accessories 7
Hydraulics A
Valid for
Abbreviations B
Control Software Version Definition of Terms C
SINUMERIK 840D 5, 6
SINUMERIK 840DE (export version) 5, 6
SINUMERIK 840Di 2 References D
SINUMERIK 840DiE (export version) 2
EC Declaration of
Conformity E
Index F
10.03 Edition
SINUMERIK Documentation
3ls
Revision history
Brief details of this edition and previous editions are listed below.
The status of each edition is indicated by the code in the “Remarks” column.
A . . . . . New documentation.
B . . . . . Unmodified reprint with new order number
C . . . . . Revised version with new edition status.
If the technical subject matter shown on the page has changed compared to the
previous edition status, this is indicated by the changed edition status in the header
of the respective page.
Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr, SIMODRIVEr and
MOTION-CONNECTr are registered trademarks of Siemens AG. Other names in this publication might be
trademarks whose use by a third party for his own purposes may violate the rights of the registered holder.
More information is available on the Internet at: Other functions not described in this documentation might be
http://www.siemens.com/motioncontrol executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
servicing.
This document was created with Interleaf V 7 We have checked that the contents of this document correspond to
the hardware and software described. Nevertheless, differences
might exist and therefore we cannot guarantee that they are
The reproduction, transmission or use of this document or its completely identical. The information given in this publication is
contents is not permitted without express written authority. Offenders reviewed at regular intervals and any corrections that might be
will be liable for damages. All rights, including rights created by patent necessary are made in subsequent editions. We welcome all
grant or registration or a utility model or design, are reserved. recommendations and suggestions.
Siemens AG, 1999-2004. All rights reserved Subject to change without prior notice
Structure of the The documentation for SIMODRIVE 611/SINUMERIK 840D is organized on the
documentation following levels:
S General Documentation
S Manufacturer/Service Documentation
S Electronic Documentation
The description of functions of the HLA module is part of the
SIMODRIVE/SINUMERIK documentation.
For further information about the publications listed in the documentation over-
view and other available SIMODRIVE/SINUMERIK publications, please contact
your local Siemens sales office.
This Description of Functions does not purport to cover all details or variations
in 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 prior
or existing agreement, commitment or relationship. The Sales Contract contains
the entire obligations of Siemens. The warranty contained in the contract be-
tween the parties is the sole warranty of Siemens. Any statements contained
herein do not create new warranties or modify the existing warranty.
Target group This documentation is intended for use by machine manufacturers and
servicing personnel who use the “HLA modules”.
Objective This Description of Functions provides the information required to configure and
start up the hydraulic drive module.
S Chapter 2 describes the procedures for configuring the electric and hydraulic
components.
S Chapter 3 shows how the hydraulic drive is started up with the support of a
menu-driven user interface.
S The firmware and the HLA module hardware functionality are explained in
Chapters 4 and 5.
S Chapter 6 explains how to check and interpret status displays and alarms
(hydraulic diagnostics).
Note
Hydraulics In this document, information about specific hydraulic functions
refers to functions provided by Bosch Rexroth AG.
How to use this The following guide information is provided to help you reference information in
manual this Description of Functions:
S Appendix with
- abbreviations, terms and references
- Glossary (index)
Definition of For the purpose of this manual and product labels, a “qualified person” is one
qualified persons who is familiar with the installation, mounting, start-up and operation of the
equipment and the hazards involved.
Software version The SW versions specified in this documentation refer to the SINUMERIK 840D
control system and the HLA module.
The Description of Functions applies only to the software versions specified.
When a new software version is released, the Description of Functions for that
version must be ordered.
Explanation of
symbols
Danger
! This symbol appears whenever death, severe physical injury or substantial material damage
will occur if appropriate precautions are not taken.
Warning
! This symbol appears whenever death, severe physical injury or substantial material damage
may occur if appropriate precautions are not taken.
Caution
! This symbol appears whenever minor physical injury or material damage may occur if
appropriate precautions are not taken.
Caution
This warning (without warning triangle) indicates that material damage may occur if
appropriate precautions are not taken.
Notice
This warning indicates that an undesirable result or an undesirable state may occur if the
information is ignored.
Note
In the context of this document, it is advisable to take note of the warning information.
Hotline
The hotline phone numbers appear in Chapter 8.
Should you have any questions about the documentation (suggestions, correc-
tions), please fax them to:
Fax: +49 (9131) 98-2176
Fax form: See the reply form at the end of the brochure
Danger
! Commissioning should not start until you have ensured that the machine
in which the components described here are to be installed complies with
Directive 98/37/EC.
Only appropriately qualified personnel may commission/start-up this
equipment.
The personnel must take into account the information provided in the technical
customer documentation for the product, and be familiar with and observe the
specified danger and warning notices.
When electrical devices are operated, the electrical circuits automatically
conduct a dangerous voltage.
Dangerous mechanical movements may occur in the system during operation.
All work on the electrical system must be carried out when the system has
been disconnected from the power supply.
Warning
! Proper transportation, expert storage, installation and mounting, as well as
careful operation and maintenance are essential for this device to operate
correctly and reliably.
In addition to the danger and warning information provided in the technical
customer documentation, applicable national, local, and system-specific
regulations must be taken into account.
The information given in catalogs and quotations applies additionally to special
versions of machines and equipment.
Caution
! When attaching the connecting cables, you must ensure that:
Caution
As part of routine tests, the devices undergo a voltage test in accordance with
EN 50178. During voltage testing of electrical equipment on industrial
machines in accordance with EN 60204-1, Section 19.4, all SIMODRIVE
device connections must be disconnected/removed. This is necessary in order
to avoid damaging the SIMODRIVE devices.
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.1 Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.2 Comparison of electric and hydraulic drive systems . . . . . . . . . . . . . 1-16
1.3 Structure of an electro-hydraulically-controlled drive axis . . . . . . . . 1-18
1.3.1 Machine guideway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.3.2 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 the hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.3.5 Hydraulic power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.4 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.4.1 Internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.4.2 External power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.4.3 Grounding concept/Electromagnetic compatibility (EMC) . . . . . . . . 2-48
3 Installation and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.1 Overview of start-up process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.2 Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.3 Modify drive machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3.4 Valve selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.5 Cylinder selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.6 Mounting/supply data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.7 Measuring system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.8 Modifying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.9 Fine adjustment and optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
B Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-257
C Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-259
D References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-261
D.1 Electrical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-261
D.2 Hydraulic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-274
E EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-275
F Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-279
Applications The NCU 573.2 of the SINUMERIK 840D is capable of handling axis configura-
tions of a maximum of 31 axes on up to 10 different channels. This functional
sophistication makes the SINUMERIK 840D an increasingly popular system for
the automation of rotary indexing machines. These machines are often highly
compact in design and frequently equipped with hydraulic axes (cylinders and
servo solenoid valves). The hydraulics (HLA) module provides a means of con-
trolling hydraulic axes directly from the SINUMERIK 840D system via the digital
drive bus.
The HLA module is a closed-loop control plug-in unit of the modular
SIMODRIVE 611 converter system mounted in a 50 mm carrier module
(universal empty housing).
The gating and closed-loop control electronics for operating controlled hydraulic
drives are integrated on the HLA module.
From the point of view of the manufacturer of modern servo solenoid valves, an
innovative step in the field of hydraulic drive systems has been taken by treating
electric and hydraulic drives as equal partners and integrating them into a stan-
dard NC.
Objective To place equal emphasis on the functional importance of both hydraulic and
electric drives and make them available as a combined system within an inter-
polating axis grouping.
Interfaces
S Firmware
The communications interface is compatible with the SIMODRIVE 611D
SRM(FDD)/ARM(MSD) for supported services. Code and data management
is analogous to the SIMODRIVE 611D SRM(FDD)/ARM(MSD). The hydrau-
lics software is stored as a separate program code in the control system.
S Hardware
The mode of integration into the SIMODRIVE 611 system is compatible with
the SIMODRIVE 611 digital SRM(FDD)/ARM(MSD). This basically involves
the following interfaces:
- Drive bus
- Device bus
- Power supply system
ments
quirements of the S Problematic with lim- and compact.
electric part on the ited mounting space. S Transfer of E motor to
machine table. hydraulic power unit.
Mass inertia of Electric part on machine Servomotor and leads- Piston and piston rod have
moving parts table has low mass. crew have high mass mo- very low mass
ment of inertia.
Operational Service life depends in S Shock-sensitive. S Protected against overload
reliability, principle only on linear
service life guides.
S Service life limited by by pressure limitation.
leadscrew. S Sturdy, insensitive to
S Sudden failure shocks.
possible. S Cylinder seals and valve
control edges have long
service life.
S Warning of wear.
Servicing Simple replacement Expensive replacement S Simple error diagnosis
and repair of leadscrew by
specialists.
S Simple replacement and
repair of valves and cylin-
ders.
Energy storage Peak requirement must Peak requirement must be S Compensation of energy
be installed as no storage installed as no storage is requirement peaks by hy-
is possible. possible. draulic accumulator.
S Rapid traverse in differen-
tial circuit.
S Reduction of installed ca-
pacity.
Maximum Peak thrust per unit area Restriction with larger Practically unlimited
forces approx. 40 to 80 kN/m2 forces. (cylinderφ, pmax=700 bar)
Load stiffness Very good; S Elasticity under large S Oil compressibility is com-
Servo gain can be set to forces. pensated as a control
betw. 10-100 times
higher than on the other
S Elasticity of leadscrew function (I component).
two drives.
is largely compen- S Good zero overlap quality
sated as a control of valve ensures very high
function. rigidity under load.
maximum ve- Up to 500 m/min vmax=hs @ ωmax/2π 30...300 m/min
locity hs=thread lead (depending on which cylinder
ωmax=max. motor speed seal kit is used)
Maximum Unlimited v6m v3m
travel path
Collision Mechanically difficult Mechanically possible Mechanically possible
protection
Electric Hydraulic
Spindle speed -
Velocity Velocity
Current flowrate
DC link voltage System pressure
Power Flow rate @ Valve pressure differential
Transistor/power section Valve
Motor Drive cylinder
SINUMERIK 840D,
SIMODRIVE 611 digital
with HLA module Servo solenoid value with
valve amplifier (OBE)
Machine guideway
Shutoff valve
Position
Hydraulic power unit measuring
system
Guide mechanism Hydrodynamic and hydrostatic slideways or roller slideways allow machine
slides and tables to move in straight lines with minimum friction and maximum
precision.
1.3.2 Cylinder
Construction The cylinder represents the simplest form of linear motor and can be integrated
easily into the machine guide. The cylinder normally has a piston rod at one
end.
Task This is the final control element in the closed control loop and forms the electro-
hydraulic converter.
Function The valve steplessly converts electrical signals into a hydraulic flow.
Its quality is defined by static and dynamic parameters, such as
S Zero overlap
S Hysteresis
S Limit frequency, etc.
This circuit contains the power electronics for the solenoid in the servo solenoid
valve 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 output value
(U=0..."10 V).
Shut-off valves are used to add safety functions to a valve control with servo
solenoid valve. Shut-off valves can prevent uncontrolled motion of the cylinder.
Task The position measuring system supplies the actual value for the position of the
moving machine element.
Function The speed is acquired by continuous differentiation of the distance over time.
Various systems are available depending on the level of accuracy required.
The highest accuracy requirements are fulfilled by digital systems (glass scale
with 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.
SINUMERIK controls and SIMODRIVE drive systems are specially designed for
machine 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 procedure for configuring an HLA module is divided into steps in such a
way that the user is guided through the full range of relevant settings, from the
required force, to the hydraulics components, and finally the HLA and its en-
coder evaluation circuitry. This initial configuring phase may be followed by a
second in some cases, in which the corresponding circuit recommendations
and EMC measures are taken into account.
The functions of SIMODRIVE components are described with keywords in this
Planning Guide. Limit values for functions may be specified in some cases.
For further details (e.g. characteristics), please refer to the Installation and
Start-Up Guides for SIMODRIVE 611 digital and SINUMERIK 840 digital.
Further configuring instructions and detailed ordering information can be found
in Catalogs NC 60 and NC Z.
Phase 1
Selection of hydraulic Section 2.3
components
and publication from Bosch Rexroth AG
Dimensioning of incoming Section 2.2
mains supply
and publication 6SN1197-0AA00
Dimensioning of
power modules Section 2.2
and publication 6SN1197-0AA00
Dimensioning of external
power supply Section 2.4
Phase 2
Recommended circuits
EMC measures Section 2.4
Block diagrams/
Section 2.2
connection diagrams
Abbreviations,
Appendix
terms and index
S Selection of the cylinder on the basis of forces and velocities required and
the cylinder mounting conditions in the machine
(see Subsection 2.3.1).
S Selection of the servo solenoid valves on the basis of the cylinder data,
forces, velocities and dynamic requirements (see Subsection 2.3.2, 2.3.3).
S Selection of the position measuring system and optionally the pressure sen-
sors with regard to the measuring range, accuracy and linearity (see Section
7.1, 7.3).
S Dimensioning of the hydraulic power unit, taking all loads into account (see
Subsection 2.3.5).
Hydraulic NC axes
Address: Department:
Phone:
Machine:
Axis: Function/designation:
Straight-cut control: Continuous-path control:
Drive specification
Components A complete SINUMERIK 840 digital control system with HLA module consists of
various individual components. These are listed below.
Table 2-1 Components of SINUMERIK 840 digital control with HLA module (number,
component, description)
Table 2-1 Components of SINUMERIK 840 digital control with HLA module (number,
component, description)
Note
An HLA module must never be operated directly on a SIMODRIVE monitoring
module, i.e. it must always be connected via a mains infeed module.
For information about connecting further additional SIMODRIVE monitoring
modules in configurations with several HLA modules, please refer to the
Planning Guide for SIMODRIVE 611 Converters /PJU/.
In a multi-tier configuration, all the infeed supply units must be connected
simultaneously.
Floppy
G4
ÄÄ
ÄÄ
MMC CPU D
J G1
S7-300
L
C
H1
H5
F
MCP
H4
G2
H6
M
(GND)
E
H8
B
B1
N
I1 O
H10
G3
K
Device bus
A
I Position sensing
MS NCU HLA
module
H11
H12 Pressure sensor A
H2 Battery and plug-in fan
unit Pressure sensor B
H3
Digital I/O
H9 (high-speed NC I/O)
Measure-
Servo solenoid
ment (2x) valve
Handwheel BERO
(2x) (1x of M) inputs
SITOP power Shutoff valve
Enable
(external PS)
P
External 26.5 V Note:
supply Display of hydraulics for one axis
-X102
Position Position
measuring measuring
system system
B B
O O
-X1 12
-X1 11
-X122
X431 X432
-X35
-X34
X1341
74
Relay contact, NC
Ready to operate contact 73.1
message 73.2 X111
NO
contact 72
Relay contact for group message 5.3
I2t and motor overtemperature 5.2
5.1
Power disable 63
Enabling voltage 9 X121
Enabling voltage 9
Drive enable 64
Reference potential for enable voltage 19
P24 7
P15 45
N15 44
N24 10 X141
M 15
M 15
RESET (R+term.15) R
1)
Enabling voltage 9
Setup mode 112
Contactor energization, start 48
Signaling contact, 111 X161
213
line contactor 113
1)
NS1 X171
Enabling signal for internal line contactor NS2
AS1 X172
Signaling contact for starting lockout (NC contact)
AS2
LED displays
X351
DC link power supply for bridging line failures M500
P500
Electronics power supply from external source 2U1
1U1 X181
Electronics power supply from external source 2V1 Device bus
1)
1V1
Electronics power supply from external source 2W1
1W1
P600
DC link
connection
LED displays M600
5 V voltage level
Electronics power Red Red fault
supply faulty
Device ready
Device is not ready, Green Yellow (DC link
no enable signal precharged)
(term. 63, 64 or 48)
Red Red DC link
Line fault overvoltage
Fig. 2-5 Interfaces on mains supply module (OI and I/RF module)
50 mm carrier module
(universal empty housing)
Shield connection (6SN1162-1AA00-0AA0)
Slotted screw
M3 / 0.8 Nm
P600
M4 / 1.8 Nm
M600
Order No.
Fig. 2-6 Mounting the HLA closed-loop control plug-in module in 50 mm carrier module (universal empty housing)
General Hydraulic drives are generally configured by technical sales personnel from the
hydraulics supplier, Rexroth.
The configuration is based on the data from the questionnaire in
Subsection 2.1.2 .
Please refer to Appendix A for a description of hydraulic components.
The hydraulic drive is configured in the sequence of steps described below.
Piston and rod The piston and rod diameters are calculated according to Pascal’s theorem on
diameter the basis of the necessary compressive and tensile forces F and a standard
pressure value of P=40...100 bar for machine tools (a maximum pressure set-
ting of 350 bar is permitted).
F
p=
O
The force value calculation must include friction and acceleration forces
as well as the actual feed force. Pistons and rods with the following standard
diameter dimensions are available:
Description 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
Stroke length The stroke is identical to the working stroke of the drive except that
it includes a few additional safety reserves.
Mounting In order to ensure good control quality, backlash-free mountings, e.g. base or
flange mountings, must be used.
Flange mounting
Flange at front
Ì ÌÌ Flange at rear
Ì
Ì ÌÌ
ÌÌ
Ì ÌÌ
Base mounting
Ì ÌÌ
ÌÌÌÌÌÌÌÌ
ÌÌÌÌÌÌÌÌ
Fig. 2-7 Cylinder mounting methods
Mounting position This is will depend on the machine’s situation and affects the choice of shutoff
valves (see Subsection 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 the operating pressure (MD 5151: CYLINDER_A_ORIENTATION).
See Fig. 4-17 in Section 4.9 for the possible cylinder mounting positions.
Seal, friction Suitable seals must be used to minimize friction. Transitions from static to slid-
ing 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 setting has been provided in the HLA module (MD 5460:
FRICTION_COMP_GRADIENT) for the purpose of counteracting initial friction.
Cylinder pipes The distance between the cylinder and servo solenoid valve must be kept as
short as possible for the sake of the drive’s natural frequency (compressibility of
the oil volume). In ideal cases, the servo solenoid valve is flange-mounted
directly on the cylinder.
Position The incremental and absolute position measuring systems supported by the
measuring system HLA module are mounted on the machine slide. It is also possible to use posi-
tion measuring systems (SSI encoders) integrated in the cylinder.
1) The characteristic values specified for the valve limit frequencies relate to an amplitude of "5% and a
phase offset in the Bode diagram of -90°, see also data in catalog supplied by Bosch Rexroth AG.
The choice of valve for a particular application is made with reference to the
following criteria.
Servo solenoid or HR (High Response) valves are characterized by their improved dynamic qual-
HR servo solenoid ity, i.e. by a higher limit frequency compared to servo solenoid valves. They
valves react with greater sensitivity to setpoint changes especially in the small-signal
range. The use of HR servo solenoid valves 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 possible
positioning accuracy.
Note that HR servo solenoid valves do not generally have a fail-safe position.
The connector is also 12-pin, rather than 7-pin as with servo solenoid valves.
Valve size The valve size is determined by the maximum flowrate QX. This maximum flow-
rate is calculated according to the law of flow:
QX=v @ A
In practice, the cylinder speeds that can actually be achieved depend on the
operating pressure, the load pressure and flow-specific characteristics of the
drive. The dimensioning is left to the hydraulic configuration engineer, who has
access to a number of design calculation and simulation programs.
Q/Qnom Q/Qnom
Valve characteristic
Rapid traverse
Linearized
10% 10% characteristic
U/Unom U/Unom
40% 40%
Machining velocity compensation
Fig. 2-8 Diagram of a knee-shaped servo solenoid valve characteristic and its correction in the HLA module
Note
Recommended selection:
Servo solenoid valves are generally recommended for applications where there
is a clear separation between machining operation and rapid traverse.
Asymmetrical It is a good idea to use valves with asymmetrical restriction cross-sections for
flowrate differential cylinders or for cylinders that are not arranged horizontally and move
characteristics large loads. This improves the hydraulic clamping of the cylinder and adjusts
the controlled system gain of the hydraulic servo-drive for both directions of
travel.
QA
Q
PA
PB
U
O B QB
P T
Fail-safe position Directly-controlled servo solenoid valves have a fail-safe position, i.e. the control
spool moves to a safe position when the valve is disconnected from the power
supply. The fail-safe position is either “closed” (A, B, P, T disabled) or “open” (A,
B and T connected and P disabled). It should be noted that the “crossed”
switching position is necessarily passed when the valve is switched on and off,
and there can be temporary responses from the cylinder at these moments.
Separate shut-off valves are therefore required in order to implement safety
functions, such as a totally safe cylinder stop.
Pilot-controlled servo solenoid valves, pilot-controlled HR servo solenoid valves
and directly-controlled HR servo solenoid valves do not have a fail-safe position
and thus do not have a safe basic position when switched off. Any safety func-
tions nmust therefore be implemented via separate shut-off valves.
P T P T
Pin assignments A distinction must be made between servo solenoid valves and HR servo sole-
noid valves.
2.5 AF
O +24 V=
B 0V Supply
C 0V Reference point for actual
D valve spool value
100k
I Setpoint 0..."10 V
100k
F Sign.
10k Actual value spool value
Protective
conductor
Shield
2.5 AF
+24 V=
0V Output stage supply
+UB 1 24 V
2 enabling of
3
4 Setpoint 0..."10 V
100k
5
100k Sign.
6
10k 0V Actual value spool value
7
8 24 V
9 Enable acknowledgement
10 +24 V =/v0.5 A
11 0V Electronics supply
24 V
Error message
Protective
conductor
Shield
Preferred range The following tables list all the servo solenoid valves and HR servo solenoid
of servo solenoid valves supplied by Bosch Rexroth AG for which technical data is stored in the
valves HLA module.
Table 2-4 NG6 directly-controlled servo solenoid valves; model code 4WRPEH 6
Table 2-4 NG6 directly-controlled servo solenoid valves; model code 4WRPEH 6
P T
24 0 811 404 649 A:40; B:201) 40 O B
P T
Table 2-5 NG10 directly-controlled servo solenoid valves; model code 4WRPEH 10
1) Asymmetrical characteristic
Table 2-6 NG10 pilot-controlled servo solenoid valves; model code 4WRLE 10
Table 2-7 NG16 pilot-controlled servo solenoid valves; model code 4WRLE 16
Table 2-8 NG6 directly-controlled HR servo solenoid valves; model code 4WRREH 6
Table 2-9 NG10 pilot-controlled HR servo solenoid valves; model code 4WRVE 10
1) Asymmetrical characteristic
Table 2-10 NG16 pilot-controlled HR servo solenoid valves; model code 4WRVE 16
1) Asymmetrical characteristic
General The shutoff valves are automatically enabled and disabled in the correct switch-
ing sequence by the HLA module.
Start condition: The hydraulic pressure must be available before
the system is switched on.
Warning
! In the event of sudden failure (e.g. open circuit) of the external 24 V supply, an
axial storage capacitor on the HLA module provides energy to supply the servo
solenoid valve until such time as the pressure supply for a configured shutoff
valve is disabled.
The machine manufacturer must verify the interaction between valves, making
allowance for all tolerances in the controlled system.
The energy content of the storage capacitors is dependent upon
O B
Servo
b solenoid
SU
valve
P T
a Shut-off valve
(electrically
P T B O switched)
The circuit in Figure 2-14 achieves a high level of safety. In this case, an addi-
tional barrier block closes the consumer connections to the cylinder safely and
with no leakage of oil. This means that even heavy loads on non-horizontal axis
can be quickly stopped and held safely, regardless of the state of the servo so-
lenoid valve. Totally safe scenarios for switching the drive on and off can thus
be implemented.
O B
Servo
b solenoid
SU valve
P T
Shutoff valve
(barrier block)
Shutoff valve
a (electrically
switched)
P T B O
Fig. 2-14 Typical example for the combination of an electrically-switched shut-off valve
with an additional barrier block
Preferred range Bosch Rexroth shut-off valves from the following table should ideally be used
of shut-off valves in conjunction with the HLA module. These are sandwich-plate valves in sizes 6
and 10. Additional shut-off valves are available upon request from Bosch Rex-
roth.
P T O B
0 811 024 125 6 P T’ A’ B’
’
P T O B
0 811 024 123 6 P T’ A’ B’
’
b
P T O B
0 811 004 102 6 A B P’ T’
’ ’
a
O B P T
0 811 004 103 6 A T B’ P’
’ ’
b
O T B P
0 811 004 104 6 B T A’ P’
’ ’
a
B T O P
0 811 024 122 6 A B T’ P’
’ ’
a b
O B T P
0 811 024 121 6 P A B’ T’
’ ’
P O B T
Servo gain The possible servo gain is essentially determined by the natural frequency of
the cylinder and its load ω0 and the limit frequency of the servo solenoid valve
ωv.
The cylinder and its load constitute a spring/mass attenuation system whose
natural frequency is calculated using the following formula:
AR
O m
4 @ E @ A ( 1 + α)
wo X
m@h 2
h
Natural frequency The natural frequency of the hydraulic drive is automatically calculated by the
HLA module and applied in the controller once the corresponding data parame-
ters have been set. See machine data, Sections 4.8 and 4.9:
S MD 5131: CYLINDER_PISTON_DIAMETER
...
MD 5136: CYLINDER_DEAD_VOLUME_B
S MD 5140: VALVE_CYLINDER_CONNECTION
...
MD 5143: PIPE_INNER_ DIAMETER_A_B
S MD 5150: DRIVE_MASS
...
MD 5152: CYLINDER_FASTENING
S MD 5160: PISTON_POS_MIN_NAT_FREQ
...
MD 5163: DRIVE_NATURAL_FREQUENCY
Possible The dynamic response of the servo solenoid valves thus depends on the ampli-
dynamic response tude of the valve modulation. For valves that are used in controlled axes, the
natural frequency is typically determined for a modulation amplitude of "10%
and a phase offset of -180°. The relevant information is given in the valve
manufacturer’s catalog, e.g. /BR1/.
For pilot-controlled servo solenoid valves, the dynamic response is determined
by the pilot pressure ppilot , in addition to the valve type:
f0 ~ pbefore
Pressure p The pressure is determined from the cylinder geometry, hydraulic characteristics
of the servo solenoid valve and other data such as load forces or flow resist-
ance values in the hydraulic circuit due to the drive speeds and forces required.
The standard value for the system pressure for machine tool feed drives is
around 40... 100 bar.
Flow rate Q The maximum flowrate is calculated from the rapid traverse velocity.
If several cylinders are operating simultaneously, the sum of all loads must be
taken into account.
Maximum flow is often reached for only brief periods and can be supplied by an
accumulator.
The pump capacity is selected to satisfy the mean flow rate.
Drive power P The power P output by the electric motor to the pump drive is calculated as the
product of pressure p, flow rate Q and efficiency η.
P=p@Q@η
Pump type Variable displacement pumps with pressure regulators in combination with an
accumulator are generally employed in order to prevent power losses and to
match the energy supply to the fluctuating delivery requirement during the cycle.
Vane pumps have proven successful in the normal pressure range for these
applications of 70 to 210 bar.
Axial piston pumps are commonly used for high-pressure applications up to 350
bar.
Filtration 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.
To ensure general operational reliability, but more importantly, to protect the con-
trol edges against premature erosion and to maintain the quality of zero overlap,
the oil contamination must be limited in compliance with
Class 7...9 according to NAS 1638.
This is achieved by using class β10=75 full flow filters, which must be positioned
in the pressure line directly upstream of the servo solenoid valve.
The most critical phase is start-up, since contamination which has “accumu-
lated” prior to installation often causes failures. For this reason, it is advisable to
purge the system before the servo solenoid valves are fitted.
Cooling Since considerable power losses that cannot be compensated for solely
through oil reservoir dissipation occur when the flow is throttled via the control
edges on the valve, additional oil/air or oil/water heat exchangers must be pro-
vided in most cases.
°C
P
Q
M
(GND)
2.4 Connection
Comments
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 to
use the supply provided could damage the unit.
Connection and The HLA module is integrated as a single module into the network of
power loss SIMODRIVE modules (power supply or incoming supply module, possibly feed
calculation for the modules and/or main spindle modules) and 840D. The power supply is fed in
NCU via the device bus.
The total power requirement for the entire network must be calculated. This
must not exceed the power supplied by the power supply module.
To make the calculation easier, each module has a weighting factor.
This can be found in Chapter 9 of the following reference material:
References: NC 60 catalog
The sum of electronic and control points must not be larger than stated in the
data sheet of the power supply module.
Requirements of The purpose of the external power supply is to switch and supply the hydraulic
external 26.5 V components
supply
S closed-loop proportional valves
S Shutoff valves
S pressure sensors
via the closed-loop control.
In principle, stabilized or unstabilized power supplies and switched-mode or
in-phase-controlled supplies can be used.
The following points must, however, be noted:
S 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.
S The stabilization has 24000 µF input capacity per module, which can best
be charged up with a stabilized power supply (with current limitation).
Warning
! S The DC supply must be safely electrically isolated.
See also:
References: /PHD/, Configuration NCU 561.2-573.2
S 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 X431
to supply the hydraulics components (servo solenoid valves, shut-off valves,
and pressure sensors). The power requirements is calculated from the
power required by external components plus 0.1 A for the internal circuit.
The input voltage tolerance relates 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 the
control.
Caution
! After the external 26.5 V supply has powered up, terminal X431 may no longer
be inserted or switched since the high charging currents can irreparably
damage the module or external switch.
Recommended The SITOP power product range supplied by SIEMENS is recommended for
power supply use as the external 26.5 V power supply.
References: SITOP catalog
Order no. E86060-K2410-A101-A4
X431
P24EXTIN
5 M24EXTIN
6
X131
L1 SITOP M (GND)
L2
Line L3 L+ (26.5 V)
AC/DC
PE
Fig. 2-16 Connection of external 26.5 V SITOP power for line connection
ÏÏÏ
ÏÏÏ
Gating HLA module Distribu-
electronics tion box
ÏÏÏ
NCU
PA/SL
Operator panel Machine
MMC
control panel
PA/SL PA/SL MB
- Ground (frame) -
MB
Terminal
S7-300 I/Os
block
PA/SL Hydraulic drive PA/SL
PA PA
Machine bed
Machine The hydraulic linear drive (HLA) is displayed as follows next to the electric
Configuration drives (SRM, ARM and SLM) in the “Machine Configuration” screen (basic
start-up display):
Machine Data Hydraulic linear drives (HLA) are adapted to suit the machine using the machine
data.
In addition to the following soft keys:
S General MD
S Channel MD
S Axis MD
S Display MD
Softkey “Drive MD”.
Start-up sequence The following list shows the general steps to be taken to start up an HLA mod-
ule.
1. Select a valve ³ Select a valve from the list
2. Enter cylinder data
3. Mounting/supply data
4. Measuring system data
5. Calculate controller data, save boot file, NCK reset.
6. MD 5474: OUTPUT_VOLTAGE_POS_LIMIT and
MD 5475: OUTPUT_VOLTAGE_NEG_LIMIT
to low values to 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” using this machine data or
automatically via MD 5650. Enter 1000 Hex in MD 5650. The data is reset to
0 after approximately 2 s and the sensors are then adjusted. The sensors
must be unpressurized during adjustment.
9. Run offset compensation MD 5470.
Automatic offset compensation can be run via MD 5650 if 2000 Hex is en-
tered in MD 5650. Automatic offset compensation takes approximately 30 s
and functions only if the P and I components of the velocity controller are
active 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 in
the positive and negative traversing directions is almost identical.
12. Force limitation and friction torque compensation, see Section 4.4.
The selected drive type (hydraulic linear drive in this example) is stored in NC
machine data MD 13040: DRIVE_TYPE stored.
S MD 30110: CTRLOUT_MODULE_NR
S MD 30130: CTRLOUT_TYPE
S MD 30220: ENC_MODULE_NR
S MD 30240: ENC_TYPE
has been entered and an NCK power ON reset has been carried out (taking you
to the “Drive Machine Data” menu display), the drive can be started up.
Drive + Drive +
Drive - Drive -
Direct Direct
selection... selection
Valve/ Valve
Controller... selection... (See Fig. 3-6)
Search... Calculate
controller (See Fig. 3-15)
data...
Continue Piston
(See Fig. 3-21)
search position...
Display <<
options...
File File
functions functions
General You can select the servo solenoid valve from a list when you start up the SIMO-
DRIVE 611 for the first time. Once you have made your selection, the valve ma-
chine data defaults are overwritten.
If the valve you want to use is not included in the list, you must enter the valve
machine data manually.
“Valve selection...” This soft key starts the user-prompted start-up process for the HLA module.
soft key You can select a valve from a list stored in the module software, or a non-listed
valve, in the following menu display.
Enter “Unlisted valve” to call a new menu display (see Fig. 3-7) in which the
corresponding machine data can be entered manually.
Choose softkeys “Search...” and “Continue search” to look for any character
string within the list.
Select softkey “Back” to return to the previously displayed menu. This
softkey is disabled in the menu display 3-6.
Note
When you select “Abort”, the program branches back to the drive machine data
display (see Fig. 3-5), both in this screen and the following menu displays for
user-prompted start-up. The “Abort” soft key also activates a prompt box in
which you must confirm that you really want to abort start-up for this drive.
No data is ever changed when you select “Abort”. This also applies to the
following menu displays.
From 10.03 onwards, the name of the company will be changed from Bosch to
Rexroth in the menu displays. The order numbers will remain unchanged.
If the “Unlisted valve” entry is selected, press the “Continue” soft key to go to the
“Unlisted Valve Data for HLA” menu display (see Fig. 3-7). If you press softkey
“Continue” otherwise, the machine data assigned to the entry are written to a
buffer whose contents are transferred to the drive at the end of the start-up pro-
cess. The “Cylinder data” menu display then appears (see Fig. 3-9).
Valve selection The following data appears in the MMC list display for a stored valve when you
from a list select one:
S Code e.g.: 52
Loaded If you select a valve from the list, the following machine data is preset (i.e. the
valve data default value is overwritten):
Unlisted valve data You must enter the valve machine data manually for an unlisted valve. You can
also preset the machine data to the settings of a similar valve.
Press the “Continue” softkey to call menu display “Cylinder data”. This data is
not written to the drive until start-up has ended.
By pressing vertical softkey “Preset”, you can go to the corresponding menu
display in which you can preset machine data by selecting “OK”. You then re-
turn to menu display “Unlisted valve data for HLA”.
When you press “OK”, the machine data in menu display “Preset unlisted valve
for HLA” are preset. You then return to this menu display.
S MD 5131: CYLINDER_PISTON_DIAMETER
(piston diameter of cylinder)
S MD 5132: CYLINDER_ROD_A_DIAMETER
(cylinder piston rod diameter at A end)
S MD 5133: CYLINDER_ROD_B_DIAMETER
(cylinder piston rod diameter at B end)
S MD 5134: PISTON_STROKE
(piston stroke)
S MD 5135: CYLINDER_DEAD_VOLUME_A
(cylinder dead volume at A end)
S MD 5136: CYLINDER_DEAD_VOLUME_B
(cylinder dead volume at B end)
Select the “Back” softkey to return to the “Cylinder data for HLA” menu display.
Then press “Continue” to go to the “Measuring system data for HLA” menu dis-
play.
The following mounting and supply data must be entered manually.
Supply unit
S MD 5100: FLUID_ELASTIC_MODULUS (modulus of elasticity of
hydraulic fluid)
S MD 5101: WORKING_PRESSURE (system pressure)
S MD 5102: PILOT_OPERATION_PRESSURE (pilot pressure, for pilot-
actuated valves only)
Connection
S MD 5140: VALVE_CYLINDER_CONNECTION
(valve-cylinder connection configuration)
Drive data
S MD 5150: DRIVE_MASS (moved mass of drive)
S MD 5151: CYLINDER_A_ORIENTATION
(mounting position A end of cylinder)
To set the encoder parameters, select either the “Incremental” or the “Absolute
(EnDat interface/SSI interface)” option.
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 selecting
softkey “Back”.
Softkey “Ready” Select the “Ready” softkey to conclude the start-up for this drive.
A dialog message then appears. This must be acknowledged with “Abort” or
“OK”.
You can return to menu display “Measuring system data for HLA” by selecting
softkey “Abort”.
Press “OK”, to write the machine data to the drive. The drive model and control-
ler data are then calculated and the boot file saved. The program then jumps to
the “Valve/Controller...” menu display (see Fig. 3-5), where data can be checked
and/or modified using “Change valve data”.
The remaining drives can then be started up.
Activation of data The entered/calculated data can be activated by an NCK power On/Reset.
Changing valve The following menu display appears when you press the “Change valve data...”
data softkey (see Fig. 3-5):
If you press “Abort”, the old machine data settings are retained and you return
to the initial menu display (see Fig. 3-5).
Softkeys “Valve data...”, “Cylinder data...” and “Mounting data...” each call a dis-
play that has the same format as the following screenshot except for display
header and contents (e.g. valve data for HLA):
You can return to menu display “Change data for HLA” (see Fig. 3-13) by press-
ing “Abort” or “OK”.
The valve and cylinder data and the mounting/supply data are used to preset
the following data when you activate “Calculate drive model data”. These set-
tings can be changed manually afterwards. It is advisable to confirm the calcu-
lated model data by carrying out tests on the drive and correct them in accor-
dance with the test results.
S MD 5401: DRIVE_MAX_SPEED (maximum useful velocity)
S MD 5440: POS_DRIVE_SPEED_LIMIT (positive velocity setpoint limit)
S MD 5441: NEG_DRIVE_SPEED_LIMIT (neg. velocity setpoint limit)
S MD 5160: PISTON_POS_MIN_NAT_FREQ (min. natural frequency,
piston position)
S MD 5161: DRIVE_DAMPING (drive damping)
S MD 5162: DRIVE_NATURAL_FREQUENCY_A (natural freq. of drive A)
S MD 5163: DRIVE_NATURAL_FREQUENCY (natural frequency of drive)
S MD 5164: DRIVE_NATURAL_FREQUENCY_B (natural freq. of drive B)
S MD 5231: FORCE_LIMIT_WEIGHT (weight force limitation)
S MD5240: FORCECONTROLLED_SYSTEM_GAIN
(controlled system gain force controller)
S MD 5435: CONTROLLED_SYSTEM_GAIN (controlled system gain)
S MD 5462: AREA_FACTOR_POS_OUTPUT (fact. area adaptation pos.)
S MD 5463: AREA_FACTOR_NEG_OUTPUT (fact. area adaptation neg.)
The data entered for valve, cylinder, mounting/supply and drive model are used
to preset the following data when you activate “Calculate drive model data”.
These settings can be changed manually afterwards.
S MD 5242: FORCECTRL_GAIN (P-gain of force controller)
S MD 5243: FORCECTRL_GAIN_RED (reduction of force controller P gain)
S MD 5244: FORCECTRL_INTEGRATOR_TIME (force controller reset time)
S MD 5245: FORCECTRL_PT1_TIME (smoothing time constant of
force contr.)
S MD 5246: FORCECTRL_DIFF_TIME (force controller D-action time)
S MD 5476: OUTPUT_VOLTAGE_INVERSION (manip. variable inversion)
S MD 5464: POS_DUAL_GAIN_COMP_FLOW
(knee compensation pos. flow rate)
S MD 5465: POS_DUAL_GAIN_COMP_VOLTAGE (knee comp. pos. voltage)
S MD 5467: NEG_DUAL_GAIN_COMP_FLOW (knee comp. neg. flow rate)
S MD 5468: NEG_DUAL_GAIN_COMP_VOLTAGE (knee comp. neg. voltage)
S MD 5406: SPEEDCTRL_GAIN_A (P gain, P gain
S MD 5407: SPEEDCTRL_GAIN (velocity controller P gain)
S MD 5408: SPEEDCTRL_GAIN_B (P gain, P gain
S MD 5409: SPEEDCTRL_INTEGRATOR_TIME[n] (vel. controller reset time)
S MD 5413: SPEEDCTRL_ADAPT_ENABLE (selection of vel. c. adaptation)
S MD 5414: SPEEDCTRL_REF_MODEL_FREQ[n] (natural freq. of ref.model)
S MD 5415: SPEEDCTRL_REF_MODEL_DAMPING[n]
(damping of velocity controller reference model)
S MD 5430: SPEEDCTRL_PT1_TIME (smoothing time constant vel. lead time)
S MD 5431: SPEEDCTRL_DIFF_TIME_A[n] (velocity controller A
derivative-action time)
S MD 5432: SPEEDCTRL_DIFF_TIME[n] (velocity controller lead time)
S MD 5433: SPEEDCTRL_DIFF_TIME_B[n] (velocity controller B)
Calculate Press “OK” (in Fig. 3-13) to transfer the modified machine data is transferred to
controller the drive and, depending on the option settings
data/drive model S calculate drive model data and/or
data
S Calculate controller data
the “Calculate controller/drive model data” dialog box 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”
Press “Abort” to return to the “Change Data for HLA” menu display
(see Fig. 3-13).
Press “OK”, to recalculate the drive model data and/or controller data and then
return to the initial menu display (see Fig. 3-5).
The filters, friction compensation and limitation parameters can then be set to
suit the application.
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.
Limitation of The manipulated voltage must be limited before the system is first switched on
manipulated for a control direction check.
voltage MD 5474: OUTPUT_VOLTAGE_POS_LIMIT [ 1 V
MD 5475: OUTPUT_VOLTAGE_NEG_LIMIT [ 1 V
Determine
control direction
(step 1) Note
It is not necessary to determine the control direction if the drive can already
operate in JOG mode. In this case, the control direction is already set correctly
(MD 32110). The control direction of the velocity controller still needs to be
checked (MD 5011 bit 0). The control direction must be set identically: both
“inverted” or both “not inverted”.
Continue from step 2.
When the enabling signals are set, the axis may move in an uncontrolled man-
ner.
Causes:
S Incorrect control direction of velocity controller
- Actual value encoder mounting
- Connections combining servo solenoid valve and cylinder
- Manipulated voltage polarity reversed
S 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
If valve end A is connected to cylinder end B (MD 5140=1), inversion of the
valve manipulated variable (MD 5476) is preset by “Calculate controller data”.
Start
Do MD 5706 and
MD 5707 (vset, vact) no MD 5476: Invert
have the same sign OUTPUT_VOLTAGE_INVERSION (manip.
when the drive variable inversion)
starts?
Step 2
Definition of drive When the cylinder piston moves in the A ³ B direction (flow rate Q > 0) , the
travel direction actual velocity value Vact must be positive.
(step 2) This definition MUST be made in the drive for the associated functionality of
S velocity controller adaptation and
S force limitation
absolutely essential.
MD 5476: OUTPUT_VOLTAGE_INVERSION
Modify bit 0 (invert manipulated variable)
Is cylinder and
no MD 5011: ACTUAL_VALUE_CONFIG Modify
piston A ! B traversing
and is MD 5707 bit 0 (invert actual value)
positive? and
MD 32110: ENC_FEEDBACK_POL
(actual value sign)
Yes
Step 3
Definition of travel The positive direction of travel of the machine is defined by the user.
direction in NC With adjustment of travel direction with setpoint MD 32100: AX_MOTION_DIR.
(Step 3)
Yes
End
Offset of pressure
sensors
Note
Only in combination with pressure sensing function.
Reference value
for pressure
sensors Note
Only in combination with pressure sensing function.
S Set MD 5650 bit 13. (Bit 13 is automatically reset after about 30 s.)
S MD 5470: OFFSET_COMPENSATION offset compensation is set automati-
cally.
Target Owing to the tolerances of the valves and drive units with
S real areas
S real valve control edges
it is advisable to readjust the controlled system gain for the purpose of obtaining
a symmetrical actual velocity.
∆vmove out = ∆vmove in
The gain is adjusted via machine data
Cylinder vact
travel-out
t
Cylinder ∆2
travel-in
v
∆1 vset
Cylinder vact
travel-out
t
Cylinder ∆2 = 0
travel-in
v
∆1 = 0
Cylinder vset
travel-out
vact t
Cylinder ∆2 = 0
travel-in
3. Adjusted state
Note
S Vset is not represented by the “servo trace” function if the setpoint is defined
by the function generator.
S The setting must be checked at different velocities.
- Generally speaking, the average value of the calculated controlled
system gain must be set or
- the gain can be adjusted to match the relevant operating range.
S Both adjustment are equivalent, i.e. adjustment by the stage 2 method via
MD 5462 and MD 5463 produces equivalent results when the preset value
(setting) of the controlled system gain (MD 5435) is applied.
Piston zeroing The position of the cylinder piston is required for the “Force controller” and “Ve-
locity controller adaptation” functions. For this purpose, the piston position must
be adjusted once after referencing.
This is done by the following sequence of operations:
Press the “OK” soft key to return to the initial menu display for HLA.
The following machine data affects the position adjustment:
Note
The piston position adjustment must be repeated if the control direction,
reference point offset or travel direction (MD 32110, MD 34090 or MD 32100) in
the axis-specific machine data is changed.
General The most important travel motions are implemented via the feedforward control
path.
The function of the controller parameters is to damp the oscillation characteris-
tics of the valve/cylinder grouping.
In this respect, we distinguish between three different scenarios relating to the
corner frequency (f):
1. fvalve << fcylinder (f)
The valve cannot actively influence any cylinder frequency that is higher
than the valve corner frequency.
Disturbances with frequencies fSt > fvalve cannot be damped.
100
Drive:
fa=500 Hz; Da=0.1
10- 1
log value
10- 2
10- 3
10- 4
10- 5
101 102 103
log f
-90
Phase angle
-180
-270
10- 3
10- 4
10- 5
101 102 103
log f
-90
Phase angle
-180
-270
100 Drive:
fa=20 Hz; Da=0.1
log value 10- 1
10- 2
10- 3
10- 4
10- 5
101 102 103
log f
-90
Phase angle
-180
-270
2. The acceptable overshoot behavior represents the upper limit for the setting.
Note
P<0 (positive feedback) may be necessary to achieve the required damping
behavior. However, this setting will degrade the control quality. Friction in
particular causes prolonged settling times.
Note
The P gain is indicated as a % of MD 5435: CONTROLLED_SYSTEM_GAIN.
P=-100% compensates the feedforward control.
Test run:
S As long as the damping effect improves, the the D-action time value can be
raised further:
S Leave D-action time at its old value if the damping effect does not improve.
(see Fig. 3-22 - f)
Like the P component setting, the optimization criterion here is the maximum
acceptable 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 damping
characteristics are only to be expected at specific points when TV}0. In most
cases TV=0 is the best choice.
Note
A second iteration loop (optimize P and D components) with further
improvements can be connected in series downstream.
Optimization of
controller S Integrator/reset time (TN)
I component
Objective: Elimination of errors in feedforward control channel.
Implementation: TN>5 ms taking the overshoot
of the valve frequency response into account.
Note
The I component is deactivated if TN=0 (MD 5409) or if the P component is
zero (MD 5406=0, MD 5407=0, MD 5408=0).
General Since the natural frequency of the cylinder changes as a function of position, it
may 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 (MD
5160), of the traversing range.
Implementation Requirement:
Note
If one end of a cylinder cannot be approached, then the adaptation process
can be limited to two interpolation points.
Note
SPEEDCTRL_ADAPT_ENABLE=1 (MD 5413) is switched through only
when the axis has been referenced and adjusted.
For f (see section 3.9.5), adaptation is deactivated in “Calculate controller
data”.
Target Contour accuracy between hydraulic and electric drives is achieved when the
drive dynamic response is set identically on the axes involved.
In addition to identical servo gain settings, it must be ensured that the step re-
sponse of the closed speed controller is “identical”.
Implementation A velocity setpoint filter of the faster axis (e.g. electric) must be set to the differ-
ence between the time constants of the closed velocity control loop (Tv, eqv).
Tfilter, el =Tveqv, hyd - Tveqv, el
v
vact, el
vw
vact, hyd
0,5
If dynamic stiffness control (DSC) is active, the DSC function must be activated
on all interpolating axes.
Save data The drive type is recorded in the MD files when drive machine data is saved.
Thus, the comment is inserted only if the entry “MdFileDriveType=TRUE” has
been set in the [Compatibility] section of INI file “ib.ini”. This setting is the de-
fault.
Load data Only MD files that are suitable for a particular drive type may be downloaded to
that drive. If you attempt, for example, to load an MD file for SLM to an HLA
module, the following message will be displayed:
S Measuring functions
- Measurement of valve control loop
- Measurement of velocity control loop
- Position control measurement
S Function generator
S Circularity test
S Servo trace
S DAC configuration
Disabled softkeys The softkey “Self-opt.AM/MSD” in the “Start-up functions” menu is also disabled
for axes with HLA since this is a special function for AM/MSD.
The “Aut. Controller setting” in the “Startup functions” menu is disabled for axes
with HLA since the algorithms it uses are designed for automatic controller set-
ting for electric digital drives.
The measurement functions can be used to evaluate the most important speed
and position control loop variables in the time and frequency range on screen
without having to use external measuring devices.
An overview of the measurement functions provided for HLA is given below.
Only the hydraulic-specific functionality for HLA is described in detail.
The following measurement functions can be performed in conjunction with the
HLA:
Note
It must be ensured that the drive is adequately lubricated before PBRS/FFT is
applied (high-frequency movement at one position).
20.000
Ampl.
[dB]
-60.000
1.000 log [Hz] 1.000e+03
+180
Phase
[degrees]
-180
1.000 log [Hz[] 1.000e+03
Fig. 3-29 Sample valve frequency response for type 4WRREH 6 HR servo solenoid
valves from Bosch Rexroth AG
Note: For setting the valve data, see Section 4.7.
Measurement of
velocity control
Table 3-4 Measurement types and measured variables for the velocity control loop
loop measurement
The following functional response in the diagrams were recorded with the equip-
ment combination below:
Valve: Type 4WRREH 6 HR servo solenoid (15 l/min, knee 60 %)
from Bosch Rexroth AG
20.000
Ampl.
[dB]
-60.000
0.100 log [Hz] 200.000
180.000
Phase
[degrees]
-180.000
0.100 log [Hz] 200.000
Fig. 3-30 Oscillogram showing reference frequency response of velocity control loop
Amplitude: 20 mm/min.
Offset: 100 mm/min.
Step change: 0 → 100 mm/min without closed-loop force control, real friction
conditions
Trace 1: Velocity setpoint
Trace 2: Actual velocity value
Fig. 3-32 Timing of disturbance step change, integral branch of velocity controller
deactivated
90.000
Ampl.
[dB]
10.000
1.000 log [Hz] 1000.000
180.000
Phase
[degrees]
-180.000
1.000 log [Hz] 1000.000
-60.000
1.000 log [Hz] 2000.000
180.000
Phase
[degrees]
-180.000
1.000 log [Hz] 2000.000
Phase margin at 0 dB
Position control
measurement
Table 3-6 Measurement types and measured variables for position feedback loop
measurement
20.000
Ampl.
[dB]
-60.000
0.100 log [Hz] 125.000
180.000
Phase
[degrees]
-180.000
0.100 log [Hz] 125.000
Valve spool
setpoint
Table 3-8 Signal (operating mode) for valve spool setpoint
(manipulated
voltage) Trigger Signal type
Valve spool setpoint in velocity controller cycle, valve Square-wave
control loop closed, velocity control loop open
Table 3-9 Signal (operating mode) for valve spool setpoint parameter settings
V
V
-2.0260
-2.0610
0.0000 t [ms] 200.0000
Fig. 3-38 Servo trace of actual valve value with square-wave signal type to valve
setpoint
Velocity setpoint
Table 3-10 Signal (operating mode) for velocity setpoint
Table 3-11 Signal (operating mode) for velocity setpoint parameter settings
Note
The following diagram was created using a servo trace.
Fig. 3-39 Servo trace of actual velocity with square-wave signal type to velocity setpoint
Position setpoint
Table 3-12 Signal (operating mode) for position setpoint
Table 3-13 Signal (operating mode) for position setpoint parameter settings
Note
The following diagram was created using a servo trace.
Fig. 3-40 Servo trace of actual position with square-wave signal type to position setpoint
Amplitude: 100 mm
The circularity test is used among other things as a way of checking the result-
ing contour precision. It works by measuring the actual positions during a circu-
lar movement and displaying the deviations from the programmed radius as a
diagram (especially at the quadrant transitions). 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 electric drive
Y1 axis: Vertical movement by hydraulic drive
Fig. 3-41 Example of circularity test on HRV size 06, 15 l/min, knee-point 60%; V=400 mm/min (traversing velocity)
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 support
function for axes with HLA module.
The following hydraulic-specific drive signals are supported by the servo trace:
Description 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 (upstream of filter) 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 value mm
Force setpoint N
Force controller control deviation N
Description Unit
P component of force controller V
I component of force controller V
D component of force controller V
Feedforward control component force controller V
Force controller output V
Zero mark signal -
BERO signal -
Physical address (drive) -
Machine data The machine data is grouped for display purposes is similarly to the machine
groups data display for electric drives.
General OEM users can add their own valves to the valve list by copying file ibhlvlvo.ini
to the “\oem” directory. 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 may
be created under “Start-up”, “MMC” or “Editor”.
Select C:\OEM, then “New”. Enter the filename ibhlvlvo.ini, followed by “OK”.
Example of an
OEM valve list
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
[DATA]
ÁÁÁÁÁÁ
;5106
ÁÁÁÁÁÁ
ÁÁÁ
,
ÁÁ
ÁÁÁÁÁÁ
,
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
, 5107, 510 510 511 5111 511 5113, 511 511 , ,
ÁÁÁ
ÁÁÁ ÁÁÁÁÁÁ
ÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
8, 9, 0, , 2, 4, 5,
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
1001= OEM, 01, abc type, 90.1, 5, 10, 10, 39.8 1, 0001B, 35, 1.0, 90, $T7ƕ40,
,
ÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁ
Á ÁÁ
ÁÁ
Á ÁÁÁÁ
1050= OEM,
ÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
02,
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
xyz type, 40.2, 5, 10, 10, 40.1 1, 0001B, 35, 1.0, 40, $T7ƕ40,
ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁ ÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
Á ÁÁÁ ,
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
1051= OEM, 03, def type, 8.1, 35, 10, 10, 10, 1, 0000B, 200, 0.8, 8, $T8,
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
1030= OEM, 04, gkl type, 100.1, 35, 10, 10, 38.5 2, 0010B, 70, 0.8, 100, $T7ƕ40,
,
$L= “End of list”
$L= “- - - - - - - - -”
Note
Columns 1 and 2 are separated by a “=” character. All other columns are
separated by a comma. Column 15 ends with a comma.
An MMC Reset must be performed to make changes effective.
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Table 3-15
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ
Meaning of individual columns
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁ
Column Description Column in Reference to MD Unit
in OEM MMC display
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
valve / max. char- Name No.
list acters
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
1
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
2
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Valve code number
ÁÁÁ
Manufacturer’s name
7/5
1/7
VALVE_CODE 5106
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
3
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Order Number
ÁÁÁ 2 / 13
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
4
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Type
ÁÁÁÁÁÁÁ 3 / 11
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
5
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
6 ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Nominal valve flow
ÁÁÁÁÁÁÁ
Nominal pressure drop of valve
VALVE_NOMINAL_FLOW
VALVE_NOMINAL_PRESSURE
5107
5108
[l/min]
[bar]
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
7
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Nominal voltage of valve VALVE_NOMINAL_VOLTAGE 5109 [V]
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
8
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Knee-point flow rate of valve VALVE_DUAL_GAIN_FLOW 5110 [%]
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
9 Knee-point voltage of valve VALVE_DUAL_GAIN_VOLTAGE 5111 [%]
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
10 Nominal flow rate ratio between 6 / 10 VALVE_FLOW_FACTOR_A_B 5112
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
A and B ends of valve
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
11 Valve configuration VALVE_CONFIGURATION 5113
12 Natural frequency of valve VALVE_NATURAL_FREQUENCY 5114 [Hz]
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
13
14
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Valve damping
Nominal valve flow rate for display 4/9
VALVE_DAMPING 5115
[l/min]
15 Valve knee-point voltage for dis- 5 / 15 [%]
play
The valve code is entered in the first column and must be a number. Numbers 1
to 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.
Language-
dependent texts Any language-dependent texts can be inserted in the OEM valve list. These all
start with $T.
Syntax: $T<X> (no semicolon)
<X> refers to a text in the language-dependent
text files
(see also language-dependent OEM texts)
Subheadings can also be inserted in the OEM valve list by adding the instruc-
tion “$L=<any text>;” at the beginning of a line. $T<X> can be used to insert
other language-dependent texts within this optional text instruction.
Language- The following language-dependent texts are predefined by the system and can
dependent be used in OEM valve lists.
system texts $T1=Order No.;
$T2=Type;
$T3=Nominal flow rate;
$T4=Knee-point voltage;
$T5=Nominal flow rate A:B;
$T6=Code;
$T7=“ Knee”;
$T8=“ Linear”;
$T9=Company;
$T10=Unlisted valve;
$T11=l/min;
Language- Language-dependent OEM display texts are stored in the \oem\language di-
dependent rectory in \ibdrv_<SPRACHE>.ini files
OEM texts <LANGUAGE> stands for the appropriate language code. This file would be
called ibdrv_gr.ini for German. The codes for all languages installed in a sys-
tem are listed in the \mmc2\mmc.ini file, [LANGUAGE] section,
LanguageList entry. Language-dependent OEM text files must be formatted as
follows:
[TEXT]
$T<X>=<any text>;
:<X> is any number w1000 and v32767, which must only occur once.
Integration in The following diagram shows how the HLA module is embedded between the
overall system control system and the hydraulic drive. The control functions of the module are
shown in greatly simplified form. They are shown in more detail in the diagram
on the following page.
Actual Actual pA
position xact velocity vact pB
P T
Valve
amplifier
Pressure supply
4-96
Fig. 4-2
Control output filter
Flowrate feedforward control MD 5280/5281
MD 5284/5285
Velocity MD 5435 MD 5288-MD 5290
Setpoint filter +
MD 5500-MD 5502/ Setpoint Control output filter Area adapt- Knee-point Manipulated voltage
limitation Velocity controller ation limitation
Block diagram of
control functions
Adaptation
4 Firmware Drive Functions
Reference to
Velocity model DAC
setpoint vset MD 5414/ I component
MD 5415 MD 5409
Offset
Limitation MD 5470
4.1 Block diagram of closed-loop control
Attenuation
P component (valve dynamic response)
F MD 5242 MD 5243
set
Adaptation
I component
MD 5244
D component
MD 5245/MD 5246
Adaptation
F
act (see Section 4.4, Fig. 4-11)
Fig.4-2 shows the functionality for velocity and closed-loop force control plus
4.2 Functions
It is possible to switch between 8 different parameter sets. Data which are as-
signed to specific parameter sets are identified by an [n] in the string code [0-7].
The request is made from the PLC by means of IS “Select drive parameter set”
DB 31-61 DBB 21 bits 0-2. They are predominantly controller and filter data
that can be switched over as a function of parameter set.
The status is interrogated by means of IS “Active drive parameter set” DB
31-61 DBB 93 bits 0-2.
Section 4.15 contains a complete parameter list with the attributes for each pa-
rameter.
PLC Change-
over block
Hydraulic cylinder
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
Press
Velocity setpoint The NC ³ drive transfer interface is normalized to the maximum velocity set in
data MD 5401: DRIVE_MAX_SPEED.
Velocity setpoint
interpolation
Dwell
Position control cycle
Velocity setpoint The complexity of applying velocity setpoint filters means that it is not possible
filter to provide generally-applicable, definitive guidelines for their use. However, cri-
teria for selecting filters and their parameters are defined below.
The velocity setpoint filters are used to adapt the velocity-controlled drive group-
ing to the higher-level position control loop. You can choose between bandstop
filters and low passes (PT2/PT1).
The task of a filter is to
S smooth the control response characteristic,
S damp mechanical resonance and
S symmetrize axes with different dynamic responses, especially the response
of interpolating axes.
Note
Low-pass filters can be employed on interpolating axis groupings to
compensate for differences in dynamic response in velocity control loops.
The total equivalent time constant (equivalent time constant of velocity control
loop + equivalent time constant of velocity setpoint filter) must be set to an
identical value for all mutually interpolating axes.
Entering damping values close to the minimum input limits results in overshoots
up to a factor of 2 in the time range.
5500 NUM_SPEED_FILTERS [n] 0...7 index of the parameter set Cross reference: -
No. of velocity filters Related to: Protection level:
0: No velocity filters active HLA 3/3
1: Velocity filter activated
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
5501 SPEED_FILTER_TYPE [n] 0...7 index of the parameter set Cross reference: -
Type of velocity filter Related to: Protection level:
Bit 0= 0: Low-pass (see MD 5502, MD 5506, MD 5507) HLA 3/3
1: Bandstop (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)
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 257 UNS.WORD Immediately
5502 SPEED_FILTER_1_TIME [n] 0...7 index of the parameter set Cross reference: -
PT1 time constant for velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.0 0.0 500.0 FLOAT Immediately
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 defined by setting
MD 5501 to PT1 or PT2 low-pass or to band-stop filter. The key data for the filter
is defined in MD 5502 to MD 5520.
The filter is deactivated if machine data MD 5502 is set to 0.
5506 SPEED_FILTER_1_FREQUENCY [n] 0...7 index of the parameter set Cross reference: -
PT2 natural frequency for velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 2000.0 10.0 8000.0 FLOAT Immediately
5507 SPEED_FILTER_1_DAMPING [n] 0...7 index of the parameter set Cross reference: -
PT2 damping for velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0.7 0.2 1.0 FLOAT Immediately
Setting the machine data to a value of < 10 Hz as the low-pass natural fre-
quency deactivates the filter.
Note
For interpolating axes, please read Subsection 3.9.7.
Amplitude log 10
frequency curve 0.2
3
0 0.5
-3
Absolute
value -10 1.0
[dB]
-20
-30
102 103 log f [Hz]
0
1.0
-90 0.5
0.2
-180
102 103 log f [Hz]
Fig. 4-5 Low-pass filter (PT2) operation at natural frequency (MD 5506) of 1000 Hz and
variations in damping (MD 5507) of 0.2, 0.5 and 1.0
5514 SPEED_FILTER_1_SUPPR_FREQ [n] 0...7 index of the parameter set Cross reference: -
Band-stop filter blocking frequency for velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 3500.0 10.0 7999.0 FLOAT Immediately
5515 SPEED_FILTER_1_BANDWIDTH [n] 0...7 index of the parameter set Cross reference: -
Band-stop filter bandwidth for velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 500.0 5.0 7999.0 FLOAT Immediately
Note
The bandwidth must be less than 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 reference: -
Bandwidth numerator of velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 0.0 0.0 7999.0 FLOAT Immediately
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 reference: -
Band-stop filter natural frequency for velocity filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 1.0 141.0 FLOAT Immediately
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 of two
velocity controller cycles
(MD 5520@0.01@MD 5514<1/(2@MD 5001@31.25 µs).
Note
MD 5522 performs no function and is only compatible with the electric drives.
Amplitude log 10
frequency curve 500 Hz 1000 Hz
3 2000 Hz
Absolute 0
value -3
[dB]
-10
-20
-30
102 103 log f [Hz]
Phase frequency
curve 180
Phase angle
[degrees]
90
-90
500 Hz 1000 Hz 2000 Hz
-180
102 103 log f [Hz]
Fig. 4-6 Frequency response of undamped band-stop with a bandwidth of 500 Hz and
variations in blocking frequency (MD 5514) of 500 Hz, 1000 Hz, 2000 Hz
Amplitude log 10
frequency curve 100 Hz
3
Absolute 0
value -3
[dB] 500 Hz
-10
1000 Hz
-20
-30
102 103 log f [Hz]
Phase
frequency curve
180
Phase angle
[degrees]
90
100 Hz
0
-90
1000 Hz
500 Hz
-180
102 103 log f [Hz]
Amplitude log 10
frequency curve
3
Absolute 0
value -3
[dB] 250
-10
150
-20 0
-30
102 103 log f [Hz]
Phase frequency
curve
180
Phase angle
[degrees]
90
150
0
250
-90
0
-180
102 103 log f [Hz]
Fig. 4-8 Band-stop behavior with bandwidth of 500 Hz, blocking frequency of 1000 Hz
and variation in numerator bandwidth (MD 5516) of 0, 150 and 250 Hz.
Amplitude log 10
frequency curve
3 1414
Absolute 0
value -3
[dB]
-10 1000
707
-20
-30
102 103 log f [Hz]
Phase frequency
curve 180
Phase angle 1414
[degrees]
90
1414 1000
0
-90 707
707
-180
102 103 log f [Hz]
Velocity setpoint The velocity setpoint is limited in the positive and negative directions.
limitation
Note
The maximum rapid traverse velocity of the drive (G0 function) is determined
by NC machine parameter 32000.
With a differential cylinder, the physically possible velocities for piston travel-out
and travel-in are asymmetrical. For this reason, it is advisable to set asymmetri-
cal limitations. A message is sent to the PLC if the limit is violated.
If setup mode is selected, then the velocity setpoint is set to the value in MD
5420 for both directions. The velocity setpoint limitation is calculated as part of
the “Calculate drive model data” operation and
MD 5440 and MD 5441 are preset accordingly.
Acceleration To protect mechanical components against excessive wear and damage, the
limitation drive acceleration setpoints can be limited by the NC. Linear interpolation of the
velocity setpoints (see MD 5004: CTRL_CONFIG, bit 12; velocity setpoint inter-
polation) ensures that the drive accelerates at the rate specified by the control.
A function for limiting the acceleration in the drive has not been implemented.
(A braking ramp is operative only if the velocity controller is disabled, see MD
5402: SPEED_CTRL_DISABLE_STOPTIME).
Servo gain The controlled system gain is entered in MD 5435 after “Calculate drive model
data” and should not be altered unless it is incorrect. The value in MD 5435 is
the reference for the P gain of the velocity controller.
5435 CONTROLLED_SYSTEM_GAIN [n] 0...7 index of the parameter set Cross reference: -
Controlled system gain Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
mm/Vmin 0.0 0.0 20000.0 FLOAT Immediately
Friction
5460 FRICTION_COMP_GRADIENT Cross reference: -
Gradient of friction compensation characteristic Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 0.0 400.0 FLOAT Immediately
5461 FRICTION_COMP_OUTPUT_RANGE Cross reference: -
Effective range of friction compensation (at output) Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.1 0.1 10.0 FLOAT Immediately
Output
100%
MD 5461
MD 5460
-100%
Input
100%
- MD 5461
-100%
Fig. 4-10 Friction compensation characteristic; see also static friction injection
in Subsection 4.4.2.
Velocity controller Sampling time with which the velocity control loop is calculated.
cycle
S Short cycle: Good dynamic response, but measurement noise from actual
velocity increases.
S Long cycle: Poor dynamic response, actual velocity values are not noisy
Recommended setting:
Increase cycle time for measuring system with wide scale graduations or large
derivative action time of D component.
Adaptation of Adaptation of the P and D components is recommended where the natural fre-
P and D quency of the servo solenoid valve is higher than that of the drive.
components
5413 SPEEDCTRL_ADAPT_ENABLE Cross reference: -
Selection of velocity controller adaptation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
S Adaptation OFF
MD 5407: SPEEDCTRL_GAIN and MD 5432: SPEEDCTRL_DIFF_TIME
are 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 interpolation
points.
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 velocity
controller are interpolated linearly between two points.
“Calculate controller data” alters the settings for the controllers and the adapta-
tion selection.
controller P component
MD 5406
MD 5408
MD 5407
Piston position
0 MD 5160 MD 5134
Derivative-action time
MD 5432
MD 5431
MD 5433
Piston position
0 MD 5160 MD 5134
Natural frequency of drive
MD 5162
MD 5164
MD 5163
Piston position
0 MD 5160 MD 5134
(min. natural frequency) (piston stroke)
O B O B
P component
5406 SPEEDCTRL_GAIN_A [n] 0...7 index of the parameter set Cross reference: -
P gain of velocity controller A Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 -100.0 1000.0 FLOAT Immediately
5407 SPEEDCTRL_GAIN [n] 0...7 index of the parameter set Cross reference: -
P gain of velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 -100.0 1000.0 FLOAT Immediately
5408 SPEEDCTRL_GAIN_B [n] 0...7 index of the parameter set Cross reference: -
P gain of velocity controller B Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 -100.0 1000.0 FLOAT Immediately
A negative P gain setting may be useful for oscillation damping. Negative gain
settings are permissible. The gain is specified in relation to the drive servo gain
setting. 100% means that if the distance-to-go is equal to the maximum speed
(MD 5440: POS_DRIVE_SPEED_LIMIT, MD 5441:
NEG_DRIVE_SPEED_LIMIT), the full nominal valve voltage will be output as
the P component.
The P gain set in MD 5407 SPEEDCTRL_GAIN is referred to the controlled
system gain set in MD 5435: CONTROLLED_SYSTEM_GAIN.
I component
5409 SPEEDCTRL_INTEGRATOR_TIME [n] 0...7 index of the parameter set Cross reference: -
Reset time of velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 50.0 0.0 2000.0 FLOAT Immediately
Integrator
feedback
5421 SPEEDCTRL_INTEGRATOR_FEEDBK [n] 0...7 index of the parameter set Cross reference: -
Time constant of integrator feedback Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.0 0.0 1000.0 FLOAT Immediately
The integrator of the velocity controller loop is reduced to a 1st order low-pass
action with the configured time constant via a weighted feedback.
S Effect:
The output of the velocity controller integrator is limited to a value propor-
tional to the difference between setpoint and actual values (steady-state
proportional action).
S Applications:
Machining motions for position setpoint zero and dominant static friction can
be suppressed but result in a permanent distance-to-go, e.g. oscillation of
the position-controlled axis at zero speed (stick-slip effect) or overshooting in
the µm-step method.
S Setting notes:
Optimize this data starting from a high value until you find the best
compromise.
The integrator feedback function is mainly used when static friction problems
are encountered, i.e. so as to suppress undesirable movements caused by
static 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 for
low velocity setpoints and stabilizes the axis at zero speed. At high velocities,
however, the effect of the I component is not restricted.
5430 SPEEDCTRL_PT1_TIME [n] 0...7 index of the parameter set Cross reference: -
Velocity controller smoothing time constant Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.25 0.25 100.0 FLOAT Immediately
5431 SPEEDCTRL_DIFF_TIME_A [n] 0...7 index of the parameter set Cross reference: -
Derivative-action time of velocity controller A (D component) Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.0 -100.0 100.0 FLOAT Immediately
5432 SPEEDCTRL_DIFF_TIME [n] 0...7 index of the parameter set Cross reference: -
Derivative-action time of velocity controller (D component) Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.0 -100.0 100.0 FLOAT Immediately
5433 SPEEDCTRL_DIFF_TIME_B [n] 0...7 index of the parameter set Cross reference: -
Derivative-action time of velocity controller B (D component) Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.0 -100.0 100.0 FLOAT Immediately
Reference model
5414 SPEEDCTRL_REF_MODEL_FREQ [n] 0...7 index of the parameter set Cross reference: -
Natural frequency of reference model Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 150.0 0.0 1000.0 FLOAT Immediately
5415 SPEEDCTRL_REF_MODEL_DAMPING [n] 0...7 index of the parameter set Cross reference: -
Reference model damping Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0.9 0.4 1.0 FLOAT Immediately
The dynamic response of the velocity control loop to control commands without
an I component in the velocity controller is simulated in the reference model. In
the ideal case of exact simulation, there is no deviation after the setpoint/actual
value 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 defined by setting the natural frequency (MD5414)
and damping (MD 5415) parameters.
Control output, Two control output filters have been implemented. As compared to the current
velocity controller setpoint filter on electrical drives, the scope of functions has been extended by
the general band stop.
5200 NUM_OUTPUT_VCTRL_FILTERS [n] 0...7 index of the parameter set Cross reference: -
Number of control output filters in velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 2 UNS.WORD Immediately
The number of control output filters in the velocity controller is set in MD 5200.
No filters are active by default. Bandstop filters and 2nd-order low pass filters
can be selected and set in MD 5201: OUTPUT_FILTER_CONFIG.
Table 4-1 Selection of number of control output filters in velocity controller
Enter the configuration for 2 control output filters. Bandstops (BS) and low-pass
filters can be selected. The variable filter parameters are entered in the associ-
ated machine data.
Note
The filter machine data must be assigned before the filter type is configured.
5201 OUTPUT_VCTRL_FILTER_CONFIG [n] 0...7 index of the parameter set Cross reference: -
Control output filter type in velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 3 UNS.WORD Immediately
5202 OUTPUT_VCTRL_FIL_1_FREQ [n] 0...7 index of the parameter set Cross reference: -
Natural frequency output filter 1 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 1000.0 10.0 8000.0 FLOAT Immediately
5204 OUTPUT_VCTRL_FIL_2_FREQ [n] 0...7 index of the parameter set Cross reference: -
Natural frequency output filter 2 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 1000.0 10.0 8000.0 FLOAT Immediately
The filter key data is defined in MD 5202 to MD 5205 and MD 5210 to MD 5215.
Enter the natural frequency for control output filters 1...2 (PT2 low-pass) in the
velocity 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 reference: -
Damping control output filter 1 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 1.0 0.05 1.0 FLOAT Immediately
5205 OUTPUT_VCTRL_FIL_2_DAMP [n] 0...7 index of the parameter set Cross reference: -
Damping control output filter 2 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 1.0 0.05 1.0 FLOAT Immediately
Enter the damping for control output filters 1...2 (PT2 low-pass) in the velocity
controller. The filters are activated in MD 5200: NUM_OUTPUT_VCTRL_FIL-
TERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.
5210 OUTPUT_VCTRL_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross reference: -
Blocking frequency output filter 1 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 3500.0 1.0 7999.0 FLOAT Immediately
5213 OUTPUT_VCRTL_FIL_2_SUP_FREQ [n] 0...7 index of the parameter set Cross reference: -
Blocking frequency output filter 2 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 3500.0 1.0 7999.0 FLOAT Immediately
Enter the blocking frequency for control output filters 1...2 (bandstop) in the ve-
locity controller. The filters are activated in MD 5200: NUM_OUT-
PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.
5211 OUTPUT_VCTRL_FIL_1_BW [n] 0...7 index of the parameter set Cross reference: -
Bandwidth control output filter 1 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 500.0 5.0 7999.0 FLOAT Immediately
5214 OUTPUT_VCTRL_FIL_2_BW [n] 0...7 index of the parameter set Cross reference: -
Bandwidth control output filter 2 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 500.0 5.0 7999.0 FLOAT Immediately
Enter the -3dB bandwidth for control output filters 1...2 (bandstop filter) in the
velocity controller.
The filters are activated in MD 5200: NUM_OUTPUT_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 reference: -
Numerator bandwidth output filter 1 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 0.0 0.0 7999.0 FLOAT Immediately
5215 OUTPUT_VCTRL_FIL_2_BW_NUM [n] 0...7 index of the parameter set Cross reference: -
Numerator bandwidth output filter 2 velocity controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 0.0 0.0 7999.0 FLOAT Immediately
Enter the numerator bandwidth for control output filters 1...2 (damped bandstop)
in the velocity controller. Entering a value of 0 initializes the filter as an unatte-
nuated bandstop filter.
The filters are activated in MD 5200: NUM_OUTPUT_VCTRL_FILTERS and
MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.
DSC The DSC (dynamic stiffness control) function is supported, allowing higher P
gain settings in the position controller. The function is implemented in the same
way as on an electrical drive. It is also activated via the control system (as on an
electrical drive).
Requirements
S Pressure sensors must be installed
S Force limitation and/or static friction injection activated
(MD 5241: FORCECTRL_CONFIG)
Where: AA AB Cylinder
A: Area
P: Pressure FB
F: Force FA
O B
PA PB
Measured value
recording
AA AB
MD 5131 MD 5131
MD 5132 MD 5133
FA FB
-
∆F=Fpiston=Fact
-
Fset
Force controller
Starting up the To start up the force controller, the measuring functions and function generator
force controller can be redirected from the velocity controller to the force controller by setting bit
8 in MD 5650. In this setting, velocity setpoints are interpreted as force setpoints
in units of kN. This mode is deactivated by clearing MD 5650, bit 8
(mm/min → kN).
S in certain machining processes for which the “Travel to fixed stop” function
must be implemented or
Static friction This compensation function is needed to compensate the effects of static fric-
compensation tion occurring when the traversing direction changes (reduction of contour er-
rors, see e.g. circularity test).
5241 FORCECTRL_CONFIG [n] 0...7 index of the parameter set Cross reference: -
Force controller configuration Related to: Protection level:
Bit 0= 0: Force limitation 1 from HLA 3/3
1: Force limitation 1 ON
Bit 1= 0: Static friction injection OFF
1: Static friction injection ON
Bit 2= 0: Force limitation 2 OFF
1: Force limitation 2 ON
Unit: Default: Minimum: Maximum: Data type: Active:
HEX 0 0 6 UNS.WORD Immediately
If a pressure sensor is installed and connected for the pressures at A and B, the
force limitation and/or static friction injection functions
in 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 the
force 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 in
MD 5234 and MD 5235 vary depending on the load.
S Static friction injection (MD 5241 bit 1=1), see Subsection 4.4.2.
S Force limitation 1 (MD 5241 bit 0=1)
Force limitation 1 is always effective, even without FFA (NC function “Travel
to fixed stop”). The force limit is specified in MD 5230. If FFA is active, the
lowest force limitation always takes effect (MD 5230 or
MD 37010 or value from FXST[x]). Reference value (100% value) of force
limit for NC is MD 5725.
If the current force limitation is exceeded, the speed controller will remain
active, even if FFA has been activated. This may lead to faults if FFA is ac-
tive. At higher velocities, this can also cause continuous alternation between
the force and velocity controller. This mode is therefore only suitable for low
velocities (<0.1 @ maximum velocity).
S Force limitation 2 (MD 5241 bit 2=1)
Force limitation 2 becomes active when the force limit value is exceeded
and FFA is active. In each case, the lowest force limitation becomes active
(MD 5230 or MD 37010 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 if
the force has already fallen below the current force limitation.
FFA
t
0
F
Fact
Flimit
t
0
mode
Fcontr. on
t
0
Force limitation tolerance band (plus/minus) about force of weight and weight
force limitation.
5230 FORCE_LIMIT_THRESHOLD [n] 0...7 index of the parameter set Cross reference: -
Force limitation tolerance threshold about weight Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
N 10000.0 0.0 100000000.0 FLOAT Immediately
5231 FORCE_LIMIT_WEIGHT [n] 0...7 index of the parameter set Cross reference: -
Weight force limitation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
N 0.0 -100000000.0 100000000.0 FLOAT Immediately
If a pressure sensor is installed and connected for the pressures at A and B, the
force limitation in MD 5241 can be activated.
The force controller then ensures that the cylinder force is limited to the
relevant values if it is threatening to exceed the value set in MD 5230 plus force
of weight (MD 5231) or to drop below the force of weight value (MD 5231) minus
the setting in MD 5230.
Since only the cylinder force is measured and regulated, it may be necessary to
allow 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 pre-
set by the NC, e.g. when traveling onto a fixed stop. The lower of the two force
limitation values is then applied.
If a pressure sensor is installed and connected for the pressures at A and B, the
static friction injection function in MD 5241 can be activated.
Static force injection should not be activated if the cylinder is required to hold a
varying force of weight. In addition, the offset of the valve manipulated voltage
and the piston position must already have been adjusted. Machine data
MD 5232...MD 5235 can be adjusted by means of a circularity test.
Velocity threshold Velocity below which zero speed and thus static friction is detected.
The force controller ensures that the force is limited to the value set in MD 5234
or MD 5235 when the velocity drops below the setting in MD 5232 for as long as
the drive is stationary.
Which of the two force setpoints is applied (MD 5234 or MD 5235) is determined
by the sign of the velocity setpoint.
Cutoff limit
The force controller is deactivated just before the setpoint is reached via the
cutoff limit (MD 5233) to prevent overshoots occurring during servo solenoid
valve actuation.
If MD 5233 is set to 100%, then the force controller is not switched off until the
force 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.
Cylinder friction The cylinder friction force at a positive or negative velocity is set in MD 5234
force and 5235 respectively.
Allowance must be made for the force of weight applied to the cylinder in MD
5234 (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, then
static force injection cannot be utilized.
Allowance must be made for the force of weight applied to the cylinder in
MD 5235 (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, then
static force injection cannot be utilized.
Feedforward Factor for setting the feedforward control gain in the force controller.
control gain of
force controller
Controlled system
gain of force
controller
MD 5240 contains the controlled system proportional gain for the force control
loop.
Since the force control loop has an integral action, a unit integrator (I-action time
of 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 the
nominal volumetric flow of the servo solenoid valve. The value should not gen-
erally 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 valve
dynamic response on different cylinders.
P component
of force controller
5242 FORCECTRL_GAIN [n] 0...7 index of the parameter set Cross reference: -
Force controller P gain Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0.0 0.0 10000.0 FLOAT Immediately
If force limitation and/or static friction injection are activated in MD 5241, the
reduction in the force controller P gain in response to large setpoint/actual value
deviations (large-signal operation) is entered in MD 5243. The P component of
the force controller must be reduced since the dynamic limitations of the actua-
tor in large-signal operation also reduce the potential dynamic response of the
control loop.
Small-signal operation is set in MD 5242.
The factor in MD 5243 specifies as a percentage the value to which a
P component of 10 V is reduced.
I component
of force controller
5244 FORCECTRL_INTEGRATOR_TIME [n] 0...7 index of the parameter set Cross reference: -
Force controller reset time Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 40.0 0.0 2000.0 FLOAT Immediately
If force limitation and/or static friction injection is activated in MD 5241, the reset
time of the force controller is entered in this machine data.
Enter a value of 0 for the reset time deactivates the I-action component.
D component
of force controller
5245 FORCECTRL_PT1_TIME [n] 0...7 index of the parameter set Cross reference: -
Force controller smoothing time constant Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.5 0.25 100.0 FLOAT Immediately
5246 FORCECTRL_DIFF_TIME [n] 0...7 index of the parameter set Cross reference: -
Force controller D-action time Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
ms 0.0 -10000.0 10000.0 FLOAT Immediately
Feedforward
control filter for
force controller
5260 NUM_FFW_FCTRL_FILTERS [n] 0...7 index of the parameter set Cross reference: -
No. of force controller feedforward control filters Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
The number of feedforward control filters in the force controller are entered in
this machine data.
Table 4-4 Selection of number of feedforward control filters
Note
The filter machine data must be assigned before the filter type is configured.
5261 FFW_FCTRL_FILTER_TYPE [n] 0...7 index of the parameter set Cross reference: -
Type of feedforward control filter in force controller Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
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
5264 FFW_FCTRL_FIL_1_FREQ [n] 0...7 index of the parameter set Cross reference: -
PT2 natur. freq. feedforward control filter1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 2000.0 10.0 8000.0 FLOAT Immediately
The filter key data is defined in MD 5264, MD 5265 and MD 5268 to MD 5270.
5265 FFW_FCTRL_FIL_1_DAMP [n] 0...7 index of the parameter set Cross reference: -
PT2 damping for feedforward control filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0.7 0.2 1.0 FLOAT Immediately
Enter damping for feedforward control filter 1 (PT2 low-pass) in force controller.
5268 FFW_FCTRL_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross reference: -
Blocking frequency of feedforward control filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 3500.0 10.0 7999.0 FLOAT Immediately
Enter the blocking frequency for feedforward control filter 1 (band-stop) in force
controller.
5269 FFW_FCTRL_FIL_1_BW [n] 0...7 index of the parameter set Cross reference: -
Bandwidth of feedforward control filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 500.0 5.0 7999.0 FLOAT Immediately
5270 FFW_FCTRL_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross reference: -
Numerator bandwidth feedforward control filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 0.0 0.0 7999.0 FLOAT Immediately
Area adaptation Various non-linear effects of valve or drive can be compensated by means of
characteristics. The characteristics are cascaded so that they can be set sepa-
rately.
5462 AREA_FACTOR_POS_OUTPUT [n] 0...7 index of the parameter set Cross reference: -
Piston surface adaptation factor, positive Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 50.0 200.0 FLOAT Immediately
5463 AREA_FACTOR_NEG_OUTPUT [n] 0...7 index of the parameter set Cross reference: -
Piston surface adaptation factor, negative Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 50.0 200.0 FLOAT Immediately
Output
100%
MD 5462
-100%
Input
0 100%
-100%
- MD 5463
-200%
Linearization of
valve
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 range
in the compensation characteristic is also rounded. The rounding is based on a
root characteristic in such a way that the intersection points lie on a continuous
tangent; the rounding range can be set as required. Fig. 4-15 shows a sample
characteristic and illustrates how the associated machine data works.
The knee point is defined by the percentage for input (voltage) and output
(flow).
Q
100%
MD 5485
MD 5464
MD 5468
-100% MD 5480
MD 5488 MD 5484
U
MD 5481 MD 5486 MD 5466
MD 5483 MD 5465 100%
(positive/negative)
MD 5467
MD 5487
MD 5482
(positive/negative)
-100%
Fig. 4-15 Valve characteristic with breakpoint in zero, fine control and saturation ranges
5480 POS_DUAL_GAIN_COMP_Z_FLOW [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation pos. flowrate in zero range Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.01 0.01 95.0 FLOAT Immediately
5481 POS_DUAL_GAIN_COMP_Z_VOLT [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation pos. voltage in zero range Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 0.0 95.0 FLOAT Immediately
5482 DUAL_GAIN_COMP_SMOOTH_Z_R [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation rounding in zero range Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 0.0 10.0 FLOAT Immediately
5483 NEG_DUAL_GAIN_COMP_Z_FLOW [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation neg. flow in zero range Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.01 0.01 95.0 FLOAT Immediately
5484 NEG_DUAL_GAIN_COMP_Z_VOLT [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation neg. voltage in zero range Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 0.0 0.0 95.0 FLOAT Immediately
5464 POS_DUAL_GAIN_COMP_FLOW [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation pos. flow Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 10.0 0.2 95.0 FLOAT Immediately
5465 POS_DUAL_GAIN_COMP_VOLTAGE [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation pos. voltage Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 10.0 0.2 95.0 FLOAT Immediately
5466 DUAL_GAIN_COMP_SMOOTH_RANGE [n] 0...7 index of the parameter set Cross reference: -
Rounding range for knee-point compensation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 2.5 0.0 10.0 FLOAT Immediately
5467 NEG_DUAL_GAIN_COMP_FLOW [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation neg. flow Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 10.0 0.2 95.0 FLOAT Immediately
5468 NEG_DUAL_GAIN_COMP_VOLTAGE [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation neg. voltage Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 10.0 0.2 95.0 FLOAT Immediately
Note
A constant machining velocity of the drive directly at the knee-point of the valve
is not recommended.
5485 POS_DUAL_GAIN_COMP_S_FLOW [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation pos. flow saturation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 0.2 100.0 FLOAT Immediately
5486 POS_DUAL_GAIN_COMP_S_VOLT [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation pos. voltage saturation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 0.2 100.0 FLOAT Immediately
5487 NEG_DUAL_GAIN_COMP_S_FLOW [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation neg. flow saturation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 0.2 100.0 FLOAT Immediately
5488 NEG_DUAL_GAIN_COMP_S_VOLT [n] 0...7 index of the parameter set Cross reference: -
Knee-point compensation neg. voltage saturation Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
% 100.0 0.2 100.0 FLOAT Immediately
Q [%]
100
90
MD 5485 = 90%
MD 5486 = 70%
70 100 U [%]
For a more detailed explanation, see also Subsection 2.3.1 and Appendix A.
Offset
Since the valves are operated under analog control, an offset voltage of the D/A
converter or valve amplifier may cause a zero point error and thus a position
deviation (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 triggered with MD 5650
(see Subsection 3.9.2).
Note
When closed-loop force control is active (MD 5241), offset compensation is
absolutely necessary because the I component of the velocity controller is
deactivated with closed-loop force control.
5280 NUM_OUTPUT_FILTERS [n] 0...7 index of the parameter set Cross reference: -
Number of control output filters Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
The number of control output filters must be set in this machine data.
Table 4-6 Selecting the number of control output filters
Note
The filter machine data must be assigned before the filter type is configured.
5281 OUTPUT_FILTER_TYPE [n] 0...7 index of the parameter set Cross reference: -
Type of control output filter Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
5284 OUTPUT_FIL_1_FREQ [n] 0...7 index of the parameter set Cross reference: -
Natural frequency of control output filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 1000.0 10.0 8000.0 FLOAT Immediately
The filter key data is defined in MD 5284, MD 5285 and MD 5288 to MD 5290.
Enter the natural frequency for control output filter 1 (PT2 low-pass). Setting a
value of <10 Hz for the natural frequency of the low pass initializes the filter as a
proportional element with a gain of 1, irrespective of the associated damping.
5285 OUTPUT_FIL_1_DAMP [n] 0...7 index of the parameter set Cross reference: -
Damping of control output filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
- 1.0 0.05 1.0 FLOAT Immediately
5288 OUTPUT_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross reference: -
Blocking frequency of control output filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 3500.0 1.0 7999.0 FLOAT Immediately
5289 OUTPUT_FIL_1_BW [n] 0...7 index of the parameter set Cross reference: -
Bandwidth of control output filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 500.0 5.0 7999.0 FLOAT Immediately
5290 OUTPUT_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross reference: -
Numerator bandwidth for control output filter 1 Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
Hz 0.0 0.0 7999.0 FLOAT Immediately
Enter the numerator bandwidth for control output filter 1 (damped bandstop).
Entering a value of 0 initializes the filter as an unattenuated bandstop filter. The
value set in MD 5290 must not exceed twice the value set in MD 5289.
5474 OUTPUT_VOLTAGE_POS_LIMIT [n] 0...7 index of the parameter set Cross reference: -
Manipulated voltage limitation positive Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
V 10.0 1.0 10.0 FLOAT Immediately
The manipulated variable setpoint is limited in the positive direction to the value
set in MD 5474 before the D/A conversion. A message is sent to the PLC if the
limit is violated.
5475 OUTPUT_VOLTAGE_NEG_LIMIT [n] 0...7 index of the parameter set Cross reference: -
Manipulated voltage limitation negative Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
V 10.0 1.0 10.0 FLOAT Immediately
The manipulated variable setpoint is limited in the negative direction to the value
set in MD 5475 before the D/A conversion. A message is sent to the PLC if the
limit is violated.
Output value
inversion
5476 OUTPUT_VOLTAGE_INVERSION Cross reference: -
Manipulated variable inversion Related to: Protection level:
Bit 0= 0: No inversion HLA 3/3
1: Inversion
Unit: Default: Minimum: Maximum: Data type: Active:
- 0 0 1 UNS.WORD Immediately
The voltage output (manipulated variable) can be inverted in machine data MD
5476 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 Subsection 3.9.1.
Note
The elasticity of oil variable as a function of the temperature can be ignored for
industrial hydraulics.
4.7 Valve
Valve data The nominal valve data defines the key valve data at the nominal operating
point. The latter is defined by the
S Nominal flow rate,
S nominal pressure drop and
S nominal voltage.
Valves with the associated data are included in the valve selection list (see
Subsection 2.3.2).
Other valve data includes:
S Knee characteristic,
S Flow ratio,
S Dynamic definition with natural frequency and damping and
S Valve configuration.
For a more detailed explanation of valves, see Section 2.3 and Appendix A.
The flow ratio specifies the ratio between the nominal flow towards the A end
and the nominal flow towards the B end.
Special points to Machine parameter MD 5113 with control bits has been introduced to allow spe-
be noted cial valve features to be taken into account.
Cylinder data
Apart from the piston diameter (MD 5131), the rod diameters at the A and B
ends must also be specified (5132, MD 5133). On a differential cylinder, both
rod 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
(MD 5141 to MD 5143).
For a more detailed explanation of the cylinder data, see also Subsection 2.3.1
and Appendix A.
Valve-to-drive
connection
Mechanical design
of drive
Note
The mass of the drive is a critical parameter and should be calculated as
exactly as possible!
The mounting position of the cylinder (MD 5151) specifies to what degree the
force 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. If
the weight of the moved mass does not act in this direction, however, MD 5151
must 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 (MD
5152 bit 0=0).
2. The piston is stationary, the moved mass is attached to the cylinder (MD
5152 bit 0=1).
The Calculate drive model data routine calculates the weight force applied to
the cylinder from MD 5150...MD 5152 and enters the result in MD 5231.
MD 5150
Positive sign in
MD5151
Negative sign in
MD5151
MD 5150
Dynamic drive
model data
The drive is approximated as a PT2 low pass for the purpose of dimensioning
the closed-loop velocity control. The characteristic values “natural frequency”
and “damping” are calculated and preset from other drive data by the “Calculate
drive model data” function.
With MD 5180: CLOSED_LOOP_SYSTEM_DAMPING can be set to specify the
degree of damping to be applied in calculating the control loop during “Calculate
controller data”.
Example: Damping of 0.9
Slow closed-loop system with infrequent overshoots
Damping of 0.5
Fast closed-loop system with frequent overshoots
Description One measuring system can be connected per axis as a piston rod position sen-
sor.
Suitable
measuring S Incremental encoder with sinusoidal-cosine voltage signals
systems
S Absolute measuring systems with EnDat interface and sinusoidal-cosine
voltage signals
Incremental Linear and rotary measuring systems with two 1 Vpp sinusoidal voltage signals
encoder in quadrature. The internal interpolation factor of the HLA module is 2048 (high
resolution per sine period).
The sign of the actual-value sensing circuit can be reserved.
Signs are reversed by a software function.
Absolute encoder Linear and rotary measuring systems with two 1 Vpp sinusoidal voltage signals
EnDat in quadrature. The internal interpolation factor of the HLA module is 2048 (high
resolution per sine period).
The sign of the actual-value sensing circuit can be reserved.
Signs are reversed by a software function.
An additional serial interface for transmitting the absolute position according to
the EnDat protocol.
SSI absolute value Linear and rotary measuring systems with serial interface for transmitting the
encoder 1) absolute position using the SSI protocol.
The connection for measuring systems with a 24V voltage supply must be
made using signal lead 6FX8002-2CC80-1jjj via which the 24V DC en-
coder power supply can be fed in. The filter module 6SN1161-1DA00-0AA0
must be used in combination with this lead. No other type of filter may be used.
Encoders supplied by other manufacturers must be connected via adapter
leads supplied by the relevant manufacturer.
Encoders from the following manufacturers may be used, for example:
MTS: Temposonics 25-bit
Balluff Micropulse 25-bit
Visolux: EDM
Notice
The products recommended above are not manufactured by Siemens, but we
know that they are suitable for the purpose in principle. However, we can never
guarantee the quality of products supplied by other manufacturers.
1) SSI encoders are likely to have lower noise immunity due to the encoder and the 24 V power supply. The immunity to
interference can be improved as follows: By using a separate and immune 24V power supply for the measuring sys-
tems
Minimum and The minimum or maximum possible velocity depends on the position measuring
maximum system.
velocity
S Vmax: of the position measuring system must not be exceeded.
The maximum measuring velocity must be set in MD 5609:
ENC_SPEED_LIMIT (see Subsection 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
Phase error A phase error on tracks A and B can be corrected with the phase error com-
compensation pensation function.
Linear scale
graduations
The standard parameterizing machine data provided support only linear mea-
suring systems. ROD encoders must be converted by the user, i.e. the distance
traversed by the drive between two (coarse) increments must be entered. Value
0 is automatically entered if MD 5011 bit 4 is set to 0 (no linear measuring sys-
tem).
Rotary absolute value encoders cannot be implemented until software version
HLA 01.01.11 and beyond
The serial number of the indirect, absolute measuring system is read from the
encoder in set state 3 at boot and entered in MD 5025. (Exception: Linear en-
coder.) 0 is entered if an incremental measuring system is installed. This en-
coder ID notifies the NC if the encoder has been replaced and, if it has been
replaced, the NC resets the calibration identifier.
Bit 0 or 1 Description
= 00 100 kHz
7 = 01 500 kHz
7 = 10 1 MHz
= 11 2 MHz
=0 SSI encoder with incremental signal (not permitted)
9
=1 SSI encoder without incremental signal
=0 Gray code
10
=1 Dual (binary code)
=0 Right-justified format
11
=1 Fir-tree format (not permitted)
=0 Without parity bit
12
=1 With parity bit
=0 Odd parity
13
=1 Even parity
=0 No alarm bit
14
=1 With alarm bit
15 =1 With SSI encoder
The length defines the total transferred message frame length including all par-
ity or alarm bits.
Example: 24 bits + 1 alarm bit; 25 must be entered.
Every encoder manufacturer has a different name for the alarm bit, e.g. Power
Failure Bit.
Actual position
value
5040 PISTON_ZERO Cross reference: -
Piston zero in relation to machine zero Related to: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Active:
mm 0.0 -1000000.0 100000.0 FLOAT Immediately
In the machine data 5040: between the piston zero (end stop at A end) and ma-
chine zero must be set in MD 5040: PISTON_ZERO.
If the actual position is available in machine coordinates in the drive after the
reference point approach, it can be applied to calculate the piston position (e.g.
for adaptation).
Sensor adjustment
Offset adjustment
Note
For automatic offset adjustment, see Subsection 3.9.2.
4.12 Terminals
ON/OFF sequence Terminals are provided on connectors X431/X432 of the HLA module and X121
of the MS module for the purpose of implementing the ON/OFF conditions for
the HLA module.
The following overview shows the hierarchy of signals for enabling and disab-
ling the HLA.
Controller enable
term. 64 Control word Velocity
controller enable setpoint
Servo enable NC
& braking
Controller enable
ramp
error Timer
Preset
run
down
Timer
power
disable & Status
MD 5530 controller
Bit 3=1 enable
Status
OR Preset Timer Preset Timer power
run run enable
Timer Timer &
External 26.5 V down output down
available & power
enable value time
delay ON
Power enable
term. 63
Power enable &
Control word
term. 663
power
Power enable enable
NC
Power disable
error 24 V for shutoff
CLEAR
valve ON
External 26.5 V The 24 V voltage for the shut-off valve and valve electronics is supplied from an
supply external source connected via the HLA module.
This voltage source is monitored by the HLA module such that an internal
signaling bit “24 V valve supply voltage missing” is set by the hardware when
the voltage drops below a specific threshold. While the “Valve supply voltage
missing” bit is set, any power enable command will be rejected, thus setting the
“velocity controller enable” status bit to zero.
S 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.
S Recovery of 26.5 V supply voltage or after initial connection of the
26.5V supply voltage
The power is not enabled until the power enabling delay set in MD 5532 has
expired.
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 the
servo solenoid valve until such time as the pressure supply for a configured
shut-off valve is disabled.
The machine manufacturer must verify the interaction between valves, making
allowance for all tolerances in the controlled system.
The energy content of the storage capacitors is dependent upon
S the tolerances of the capacitors,
The available response time is mainly defined by
S the power required for the current machining step,
S the response time of the shut-off valves and
S the trip threshold of the servo solenoid valves.
If a shut-off valve is connected (MD 5530, bit 0=1), the switch remains open
for that time, i.e. the shut-off valve is closed.
This gives the servo solenoid valve enough time to move into the mid-posi-
tion from the fail-safe position without pressure. In such cases, the power
enabling delay 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. If
no shut-off valve is connected, zero can be entered as the power enabling
delay period.
Figs. 4-19 and 4-20 show the system response to 24 V ON and OFF for a con-
figuration with and without shut-off valve.
24 V supply
24 V missing
message
Switch for servo
closed
solenoid valve open
supply The valve supply is disconnected
Valve spool only if bit 4 in MD 5530 is set to
position zero
Backup capacitor maintains
Fail-safe 24 V for valve electronics
Switches Power enable delay
closed
Shutoff valve
open
Shutoff valve open
closed
Status bit
power enable
Fig. 4-19 Chronological sequence after connection of 24 V supply, with shut-off valve
24 V supply
24 V missing
message
Switch for servo closed
solenoid valve
supply open
Valve spool
position zero
Fail-safe
Switches Power enable delay MD 5532
closed
Shutoff valve
open
Shutoff valve open No shutoff valve connected
closed
Status bit
power enable
Fig. 4-20 Chronological sequence after connection of 24 V supply, without shut-off valve
Power enable The power enabling command (corresponding to pulse enable on an electrical
drive) can be issued and/or canceled via the following paths:
S Term. 63 (central power enable)
S Term. 663 (module-specific power enable)
S Control word (from NC)
S Error (ZK1, watchdog)
5530 CYLINDER_SAFETY_CONFIG Cross reference: -
Safety configuration Related to: Protection level:
HLA 3/3
Bit 0= 0: Without shut-off valve
1: With shut-off valve
Bit 1= 0: Central shut-off valve
1: Axis-specific shut-off valve
Bit 2= 0: No valve spool checkback
1: Valve spool checkback present
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 disconnected with PS with
shut-off valve (irrelevant without shut-off valve)
1: Servo solenoid valve supply remains connected with PS
with shut-off valve (irrelevant without shut-off valve)
The manipulated variable delay time is the time which the velocity controller
enable continues to disable after the power enable delay time (MD 5532) has
expired. This delay time is needed to allow the shut-off valve to open or, in sys-
tems without shut-off valve, to allow the valve spool to move from the fail-safe to
the zero position.
Disconnecting the shut-off valve supply
If a shut-off valve is set in MD 5530 (bit 0 or bit 1 = 1) and the supply voltage of
the servo solenoid valve is to be disconnected when the power is disabled (MD
5530 bit=0), the manipulated variable delay (MD 5531) is the time it takes until
the voltage supply of the servo solenoid valve is interrupted. The shut-off valve
can be closed during this period.
Actions on PE (ext. 24 V supply available, controllers enabled):
S If 24 V supply for servo solenoid valve was available, then 24 V supply for
shut-off valve is switched on immediately, otherwise it is not switched on
until power enable delay period has run down.
S After the 24 V supply for the shut-off valve has been switched on, the status
word “Velocity controller enable” is not set until the manipulated variable
enable delay has run down.
S If MD 5530 bit 4=0 is set, the 24 V supply for the servo solenoid valve is also
switched off when the manipulated variable enable delay (MD 5531) runs
down (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.
S If MD 5530 bit 0=0 is set (no shut-off valve), then the 24 V supply for the
servo solenoid valve is switched off immediately (servo solenoid valve
moves to fail-safe position).
Velocity controller A velocity controller enable/disable can be requested via the following paths:
enable
S Terminal 64 (central velocity controller enable)
S Control word (from NC)
S Error (ZK1)
If a velocity controller enable is requested and all the relevant enable conditions
are fulfilled, i.e.
Setup mode If the setup mode terminal (term. 112 on mains supply module) is selected, the
velocity setpoint is limited to the value programmed in MD 5420.
Function switch
4.13.1 Alarms
Power On alarms
RESET alarms
“Limit frequency
reached”
measuring circuit
Velocity controller
at limit
Valve spool
not responding
The valve spool position is returned for all Rexroth servo solenoid valves from
the preferred range (see Subsection 2.3.2). The message “Valve spool is not
responding” is output if the valve spool position exits the tolerance field of 10%
of maximum stroke around the setpoint for longer than the time set in MD 5614
when the power is enabled. This error message cannot be output if no check-
back signal is configured for the valve spool position (MD 5530).
Note
Bit 1 is only effective, if the signal number 0 is selected in
MD 1651:PROG_SIGNAL_NR.
Any memory location from address space X or Y in the data RAM can be moni-
tored for violation of a set threshold for the variable signaling function. A toler-
ance band can be set around this threshold; this is taken into account when the
threshold is scanned for violation in either direction. Any violation of the toler-
ance band is signaled to the PLC. This violation message can be linked to a
pickup and/or dropout delay. The signaling function operates in a 4 ms cycle.
Message to PLC
t
Note
The quantity to be monitored can be selected through specification of either a
signal number or a physical address, the physical address having relevance
only for Siemens servicing activities.
S MD 5621: PROG_SIGNAL_NR
S MD 5622: PROG_SIGNAL_ADDRESS
S MD 5623: PROG_SIGNAL_THRESHOLD
S MD 5624: PROG_SIGNAL_HYSTERESIS
S MD 5625: PROG_SIGNAL_ON_DELAY
S MD 5626: PROG_SIGNAL_OFF_DELAY
Note
If changes are made to machine data MD 5621 to MD 5624 while monitoring is
already active (8MD 5620, Bit 0 = 1), they do not automatically reinitialize the
PLC message, i.e. reset it to 0. If the message must be re-initialized, the
monitoring function must be switched off and on again via MD 5620, bit 0, after
the MD setting has been changed.
Enter the signal number of the memory location to be monitored by the variable
signaling function.
Note
This machine data is effective only if the signal number is set to 0 (see MD
5621).
Enter the threshold for the memory location address entered in MD 5622:
PROG_SIGNAL_ADDRESS which is to be monitored by the variable signaling
function. In combination with MD 5624: PROG_SIGNAL_HYSTERESIS, this
defines the actual value to be checked by the monitoring function (see diagram
under MD 5620, Fig. 4-21).
Note
Depending on machine data MD 5620: PROG_SIGNAL_FLAGS, the numerical
value entered in MD 5624 is interpreted as an unsigned value (bit 2 = 0) or a
signed value (bit 2 = 1).
Enter the hysteresis (tolerance band) for the memory location address entered
in MD 5622: PROG_SIGNAL_ADDRESS which is to be monitored by the vari-
able signaling function. In combination with MD 5623:
PROG_SIGNAL_THRESHOLD, this defines the actual value to be checked by
the monitoring function (see diagram under MD 5620, Fig. 4-21).
Note
Depending on MD 5620: PROG_SIGNAL_FLAGS, the numerical value entered
in MD 5624 is interpreted as an unsigned value (bit 2 = 0) or a signed value
(bit 2 = 1).
Enter the pickup delay for setting the message if the monitored quantity ex-
ceeds the set threshold (with hysteresis) (see diagram under
MD 5620, Fig. 4-21).
Note
Changing the settings in MD 5625: PROG_SIGNAL_ON_DELAY and
MD 5626: PROG_SIGNAL_OFF_DELAY affects a time watchdog that is
already running. The monitor is initialized with the new time settings.
Enter the dropout delay for resetting the message if the monitored quantity
drops below the set threshold (with hysteresis) (see diagram under
MD 5620, Fig. 4-21).
Note
Changing the settings in MD 5625: PROG_SIGNAL_ON_DELAY and
MD 5626: PROG_SIGNAL_OFF_DELAY affects a time watchdog that is
already running. The monitor is initialized with the new time settings.
Note
Machine data MD 5651 to MD 5654 are relevant only for internal Siemens
functions and must not be changed.
4.14.2 Monitor
Note
Machine data MD 5655 to MD 5659 are relevant only for internal Siemens
functions and must not be changed.
Various machine data is provided in the HLA module for diagnostic purposes.
NC diagnostic displays are available in a similar way to those used on electrical
drives.
The value in MD 5725 equals 100% of the set value from the NC program
(FXST[X]=100).
The purpose of machine data MD 5720 is to display any detected CRC errors
(cyclic redundancy check). The counter information is displayed on every read
request 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 all
cases. The “wrong” module (if installed) displays the error when the address is
incorrect.
The cylinder force is calculated from the actual pressures in A and B (provided
that pressure sensors are connected at X111/X112) and displayed in MD 5708.
This value is irrelevant if no pressure sensor is connected.
If the force controller (force limitation or friction injection) has been activated in
MD 5241, the effective force setpoint is displayed here. This can be specified
by:
Software version
Output of coded software release. The display is decimal. The character string
has the following format:
DDMMY, in which DD stands for day, MM for month and Y = last digit of year.
Example: The code for 01.06.1993 is 1063dec
Output of current software release. The display is decimal, e.g. 21000. This is
the code for SW version 2.10/00.
Processor capacity
utilization
Default value The machine data is preset to this value during start-up.
Range of values Specifies the input limits. If no range of values is specified, the data type deter-
(minimum and mines the input limits and the field is marked “∗∗∗”.
maximum)
Changes take
effect
S POWER ON (po) “RESET” key on front panel of NCU module
or disconnection and reconnection of power supply
or “NCK reset” soft key
Protection level Protection levels 0 to 7 have been used. The lock for protection levels 0 to 3
(4 to 7) can be canceled by entering the correct password (correct keyswitch
position). The operator only has access to information protected by one particu-
lar level and the levels below it.
Meanings of numbers
0 or 10: SIEMENS
1 or 11: OEM-HIGH
2 or 12: OEM-LOW
3 or 13: End user
4 or 14: Keyswitch position 3
5 or 15: Keyswitch position 2
6 or 16: Keyswitch position 1
7 or 17: Keyswitch position 0
Data type The following data types are used in the control system:
tion Version
5001 Velocity controller cycle SPEEDCTRL_CYCLE_TIME 4 2 16 31.25 µ s UNS.WORD Power On 4.3.2 1.01
5002 Monitoring cycle MONITOR_CYCLE_TIME 3200 128 3200 31.25 µ s UNS.WORD Power On - 1.01
5003 Configuration STS STS_CONFIG 0330 0 07F0 HEX WORD Power On - 1.01
5004 Configuration structure CTRL_CONFIG 1000 0 1000 HEX UNS.WORD Power On 4.3.1 1.01
5005 Encoder resolution for rotary measuring system ENC_RESOL_MOTOR 2048 128 65535 - UNS.WORD Power On - 1.01
5008 Encoder phase error correction ENC_PHASE_ERROR_CORRECTION 0.0 -20.0 20.0 Degrees FLOAT immediately 4.10 1.01
5011 Actual-value sensing configuration ACTUAL_VALUE_CONFIG 0 0 65535 HEX UNS.WORD Power On 4.10 1.01
5012 Function switch FUNC_SWITCH 4 0 65535 HEX UNS.WORD immediately 4.12 1.01
5022 Measuring steps of absolute track in motor ENC_ABS_RESOL_MOTOR 8192 0000 524287 - DWORD Power On 4.10 1.01
5023 Diagnosis meas. circ. motor abs. track ENC_ABS_DIAGNOSIS_MOTOR 0 0 BFFF - UNS.WORD immediately 4.10 1.01
5024 Linear scale graduations DIVISION_LIN_SCALE 20000 1000 5000000 nm UNS.WORD Power On 4.10 1.01
5025 Serial number of motor measuring system SERIAL_NO_ENCODER 0 0 4294967295 - UNS.WORD Power On 4.10 1.02.04
5027 Configuration of encoder IM ENC_KONFIG 0 0000H FFFFH - WORD Power On 4.10 1.02.04
5028 IM message frame length SSI NO_TRANSMISSION_BITS 25 0 25 - WORD Power On 4.10 1.02.04
5040 Piston zero in relation to machine zero PISTON_ZERO 0.0 -1000000.0 100000.0 mm FLOAT immediately 4.10 1.01
5041 Machine zero in relation to actual position zero MACHINE_ZERO_HIGH 0 -2147483647 7FFFFFFF HEX SIGN.DWORD immediately - 1.01
5042 Machine zero in relation to actual position zero MACHINE_ZERO_LOW 0 0 FFFFFFFF HEX UNS.WORD immediately - 1.01
5101 System pressure WORKING_PRESSURE 0.0 0.0 700.0 bar FLOAT Power On 4.6 1.01
5102 Pilot pressure PILOT_OPERATION_PRESSURE 0.0 0.0 350.0 bar FLOAT immediately 4.6 1.01
5106 Valve code number VALVE_CODE 0 0 2000 - UNS.WORD immediately 4.7 1.01
5107 Nominal valve flowrate VALVE_NOMINAL_FLOW 0.0 0.0 1000.0 l/min FLOAT immediately 4.7 1.01
5108 Nominal pressure drop of valve VALVE_NOMINAL_PRESSURE 35.0 1.0 200.0 bar FLOAT immediately 4.7 1.01
5109 Nominal voltage of valve VALVE_NOMINAL_VOLTAGE 10.0 0.5 15.0 V FLOAT immediately 4.7 1.01
5110 Knee-point flow rate of valve VALVE_DUAL_GAIN_FLOW 10.0 0.2 95.0 % FLOAT immediately 4.7 1.01
5111 Knee-point voltage of valve VALVE_DUAL_GAIN_VOLTAGE 10.0 0.2 95.0 % FLOAT immediately 4.7 1.01
Valve flow ratio betw. A and B ends VALVE_FLOW_FACTOR_A_B 1.0 0.5 2.0 FLOAT
4.15 Parameters table
4-167
Attribute Firm-
MD no. Name in plaintext Name in NC Version Min. Max. Unit Data type Sec- ware-
Index Active
4-168
tion Version
5114 Natural frequency of valve VALVE_NATURAL_FREQUENCY 150.0 1.0 1000.0 Hz FLOAT immediately 4.7 1.01
5115 Valve damping VALVE_DAMPING 0.8 0.4 1.0 - FLOAT immediately 4.7 1.01
5131 Cylinder piston rod diameter CYLINDER_PISTON_DIAMETER 0.0 0.0 2500 mm FLOAT Power On 4.8 1.01
5132 Cylinder piston rod diameter A CYLINDER_ROD_A_DIAMETER 0.0 0.0 2400 mm FLOAT Power On 4.8 1.01
4.15 Parameters table
5133 Cylinder piston rod diameter B CYLINDER_ROD_B_DIAMETER 0.0 0.0 2400 mm FLOAT Power On 4.8 1.01
4 Firmware Drive Functions
5134 Piston stroke PISTON_STROKE 0.0 0.0 3000.0 mm FLOAT immediately 4.8 1.01
5135 Cylinder dead voltage A end CYLINDER_DEAD_VOLUME_A 0.0 0.0 200000.0 ccm FLOAT immediately 4.8 1.01
5136 Cylinder dead voltage B end CYLINDER_DEAD_VOLUME_B 0.0 0.0 200000.0 ccm FLOAT immediately 4.8 1.01
5140 Valve-cylinder connection configuration VALVE_CYLINDER_CONNECTION 0 0 1 HEX UNS.WORD immediately 4.9 1.01
5141 Pipe length at A end PIPE_LENGTH_A 0.0 0.0 10000.0 mm FLOAT immediately 4.9 1.01
5142 Pipe length at B end PIPE_LENGTH_B 0.0 0.0 10000.0 mm FLOAT immediately 4.9 1.01
5143 Internal pipe diameters at A and B PIPE_INNER_ DIAMETER_A_B 5.0 0.0 100.0 mm FLOAT immediately 4.9 1.01
5150 Moved drive mass DRIVE_MASS 0.0 0.0 50000.0 kg FLOAT immediately 4.9 1.01
5151 Cylinder mounting position referred to A end CYLINDER_A_ORIENTATION 0.0 -90.0 90.0 Degrees FLOAT immediately 4.9 1.01
5152 Cylinder mounting method CYLINDER_FASTENING 0 0 1 - UNS.WORD immediately 4.9 1.01
5160 Min. natural frequency piston position PISTON_POS_MIN_NAT_FREQ 0.0 0.0 3000.0 mm FLOAT immediately 4.9 1.01
5161 Drive damping DRIVE_DAMPING 0.1 0.01 1.0 - FLOAT immediately 4.9 1.01
5162 Natural frequency of drive A DRIVE_NATURAL_FREQUENCY_A 1.0 1.0 2000.0 Hz FLOAT immediately 4.9 1.01
5163 Natural frequency of drive DRIVE_NATURAL_FREQUENCY 1.0 1.0 2000.0 Hz FLOAT immediately 4.9 1.01
5164 Natural frequency of drive B DRIVE_NATURAL_FREQUENCY_B 1.0 1.0 2000.0 Hz FLOAT immediately 4.9 1.01
5180 Selected damping for closed-loop system CLOSED_LOOP_SYSTEM_DAMPING 0.7 0.2 1.0 - FLOAT immediately 4.9 1.01
5200 Number of control output filters in velocity controller NUM_OUTPUT_VCTRL_FILTERS 0 0 2 - UNS.WORD 0...7 immediately 4.3.2 1.01
5201 Control output filter type in velocity controller OUTPUT_VCTRL_FILTER_CONFIG 0 0 3 - UNS.WORD 0...7 immediately 4.3.2 1.01
5202 Natur. freq. control output filter 1 velocity controller OUTPUT_VCTRL_FIL_1_FREQ 1000.0 10.0 8000.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5203 Damping control output filter 1 velocity controller OUTPUT_VCTRL_FIL_1_DAMP 1.0 0.05 1.0 - FLOAT 0...7 immediately 4.3.2 1.01
5204 Natur. freq. control output filter 2 velocity controller OUTPUT_VCTRL_FIL_2_FREQ 1000.0 10.0 8000.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5205 Damping control output filter 2 velocity controller OUTPUT_VCTRL_FIL_2_DAMP 1.0 0.05 1.0 FLOAT 0...7 immediately 4.3.2 1.01
tion Version
5210 Blocking freq. control output filter 1 vel. controller OUTPUT_VCTRL_FIL_1_SUP_FREQ 3500.0 1.0 7999.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5211 Bandwidth control output filter 1 velocity controller OUTPUT_VCTRL_FIL_1_BW 500.0 5.0 7999.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5212 Num. bandwith contr. output filter vel. controller OUTPUT_VCTRL_FIL_1_BW_NUM 0.0 0.0 7999.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5213 Blocking freq. control output filter 2 vel. controller OUTPUT_VCTRL_FIL_2_SUP_FREQ 3500.0 1.0 7999.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5214 Bandwidth control output filter 2 velocity controller OUTPUT_VCTRL_FIL_2_BW 500.0 5.0 7999.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5215 Num. bandwith contr. output filter 2 veloc. controller OUTPUT_VCTRL_FIL_2_BW_NUM 0.0 0.0 7999.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5230 Force limitation tolerance threshold about weight FORCE_LIMIT_THRESHOLD 10000.0 0.0 100000000.0 N FLOAT 0...7 immediately 4.4.1 1.01
5231 Weight force limitation FORCE_LIMIT_WEIGHT 0.0 -100000000.0 100000000.0 N FLOAT 0...7 immediately 4.4.1 1.01
5234 Friction force at velocity >0 STICTION_FORCE_POS 100.0 -100000000.0 100000000.0 N FLOAT immediately 4.4.2 1.01
5235 Friction force at velocity <0 STICTION_FORCE_NEG -100.0 -100000000.0 100000000.0 N FLOAT immediately 4.4.2 1.01
5240 Force controlled controlled-system gain FORCECONTROLLED_SYSTEM_GAIN 0.0 0.0 100000000.0 N/V FLOAT immediately 4.4.3 1.01
5241 Force controller configuration FORCECTRL_CONFIG 0 0 6 HEX UNS.WORD 0...7 immediately 4.4 1.01
5242 Force controller P gain FORCECTRL_GAIN 0.0 0.0 10000.0 - FLOAT 0...7 immediately 4.4.3 1.01
5243 Reduction of force controller P component FORCECTRL_GAIN_RED 40.0 0.1 100.0 % FLOAT immediately 4.4.3 1.01
5244 Force controller reset time FORCECTRL_INTEGRATOR_TIME 40.0 0.0 2000.0 ms FLOAT 0...7 immediately 4.4.3 1.01
5245 Force controller smoothing time constant FORCECTRL_PT1_TIME 0.5 0.25 100.0 ms FLOAT 0...7 immediately 4.4.3 1.01
5260 No. of force controller feedforward control filters NUM_FFW_FCTRL_FILTERS 0 0 1 - UNS.WORD 0...7 immediately 4.4.3 1.01
5261 Type of feedforward control filter in force controller FFW_FCTRL_FILTER_TYPE 0 0 1 - UNS.WORD 0...7 immediately 4.4.3 1.01
5264 PT2-natur. freq. feedforward control filter1 FFW_FCTRL_FIL_1_FREQ 2000.0 10.0 8000.0 Hz FLOAT 0...7 immediately 4.4.3 1.01
5265 PT2 damping for feedforward control filter 1 FFW_FCTRL_FIL_1_DAMP 0.7 0.2 1.0 - FLOAT 0...7 immediately 4.4.3 1.01
5268 Blocking frequency of feedforward control filter 1 FFW_FCTRL_FIL_1_SUP_FREQ 3500.0 10.0 7999.0 Hz FLOAT 0...7 immediately 4.4.3 1.01
5269 Bandwidth of feedforward control filter 1 FFW_FCTRL_FIL_1_BW 500.0 5.0 7999.0 Hz FLOAT 0...7 immediately 4.4.3 1.01
5270 Numerator bandwidth feedforward control filter 1 FFW_FCTRL_FIL_1_BW_NUM 0.0 0.0 7999.0 Hz FLOAT 0...7 immediately 4.4.3 1.01
5280 Number of control output filters NUM_OUTPUT_FILTERS 0 0 1 - UNS.WORD 0...7 immediately 4.5.2 1.01
4.15 Parameters table
4 Firmware Drive Functions
4-169
Attribute Firm-
MD no. Name in plaintext Name in NC Version Min. Max. Unit Data type Sec- ware-
Index Active
4-170
tion Version
5281 Type of control output filter OUTPUT_FILTER_TYPE 0 0 1 - UNS.WORD 0...7 immediately 4.5.2 1.01
5284 Natural frequency of control output filter 1 OUTPUT_FIL_1_FREQ 1000.0 10.0 8000.0 Hz FLOAT 0...7 immediately 4.5.2 1.01
5285 Damping of control output filter 1 OUTPUT_FIL_1_DAMP 1.0 0.05 1.0 - FLOAT 0...7 immediately 4.5.2 1.01
5288 Blocking frequency of control output filter 1 OUTPUT_FIL_1_SUP_FREQ 3500.0 1.0 7999.0 Hz FLOAT 0...7 immediately 4.5.2 1.01
5289 Bandwidth of control output filter 1 OUTPUT_FIL_1_BW 500.0 5.0 7999.0 Hz FLOAT 0...7 immediately 4.5.2 1.01
4.15 Parameters table
5290 Numerator bandwidth control output filter 1 OUTPUT_FIL_1_BW_NUM 0.0 0.0 7999.0 Hz FLOAT 0...7 immediately 4.5.2 1.01
4 Firmware Drive Functions
5401 Maximum useful velocity DRIVE_MAX_SPEED 0.0 0.0 120000.0 mm/min FLOAT Power On 4.3.1 1.01
5402 Braking time for controller disable SPEED_CTRL_DISABLE_STOPTIME 0.0 0.0 120000.0 ms FLOAT immediately 4.12 1.01
5404 Power disable timer POWER_DISABLE_DELAY 100 0 100000 ms FLOAT immediately 4.12 1.01
5406 P gain of velocity controller A SPEEDCTRL_GAIN_A 0.0 -100.0 1000.0 % FLOAT 0...7 immediately 4.3.2 1.01
5407 P gain of velocity controller SPEEDCTRL_GAIN 0.0 -100.0 1000.0 % FLOAT 0...7 immediately 4.3.2 1.01
5408 P gain of velocity controller_B SPEEDCTRL_GAIN_B 0.0 -100.0 1000.0 % FLOAT 0...7 immediately 4.3.2 1.01
5409 Reset time of velocity controller SPEEDCTRL_INTEGRATOR_TIME 0.0 0.0 2000.0 ms FLOAT 0...7 immediately 4.3.2 1.01
5413 Selection of velocity controller adaptation SPEEDCTRL_ADAPT_ENABLE 0 0 1 - UNS.WORD immediately 4.3.2 1.01
5414 Natural frequency of reference model SPEEDCTRL_REF_MODEL_FREQ 150.0 0.0 1000.0 Hz FLOAT 0...7 immediately 4.3.2 1.01
5415 Reference model damping SPEEDCTRL_REF_MODEL_DAMPING 0.9 0.4 1.0 - FLOAT 0...7 immediately 4.3.2 1.01
5420 Max. velocity for setup mode DRIVE_MAX_SPEED_SETUP 10.0 0.0 120000.0 mm/min FLOAT immediately 4.3.1 1.01
5421 Time constant of integrator feedback SPEEDCTRL_INTEGRATOR_FEEDBK 0.0 0.0 1000.0 ms FLOAT 0...7 immediately 4.3.2 1.01
5422 Velocity threshold for integrator feedback FEEDBK_SPEED_THRESHOLD 10.0 0.0 120000.0 mm/min FLOAT immediately 4.3.2 1.01
5430 Velocity controller smoothing time constant SPEEDCTRL_PT1_TIME 0.25 0.25 100.0 ms FLOAT 0...7 immediately 4.3.2 1.01
5431 Velocity controller A D-action time SPEEDCTRL_DIFF_TIME_A 0.0 -100.0 100.0 ms FLOAT 0...7 immediately 4.3.2 1.01
5432 Velocity controller D-action time SPEEDCTRL_DIFF_TIME 0.0 -100.0 100.0 ms FLOAT 0...7 immediately 4.3.2 1.01
5433 Velocity controller B D-action time SPEEDCTRL_DIFF_TIME_B 0.0 -100.0 100.0 ms FLOAT 0...7 immediately 4.3.2 1.01
5435 Servo gain CONTROLLED_SYSTEM_GAIN 0.0 0.0 20000.0 mm/Vmin FLOAT 0...7 immediately 4.3.1 1.01
5440 Positive velocity setpoint limit POS_DRIVE_SPEED_LIMIT 0.0 0.0 120000.0 mm/min FLOAT immediately 4.3.1 1.01
5441 Neg. velocity setpoint limit NEG_DRIVE_SPEED_LIMIT 0.0 0.0 120000.0 mm/min FLOAT immediately 4.3.1 1.01
5460 Gradient of friction compensation characteristic FRICTION_COMP_GRADIENT 0.0 0.0 400.0 % FLOAT immediately 4.3.1 1.01
5461 Effective range of friction compensation FRICTION_COMP_OUTPUT_RANGE 0.1 0.1 10.0 % FLOAT immediately 4.3.1 1.01
tion Version
5462 Piston surface adaptation factor, positive AREA_FACTOR_POS_OUTPUT 10.0 10.0 200.0 % FLOAT 0..7 immediately 4.5.1 1.01
5463 Piston surface adaptation factor, negative AREA_FACTOR_NEG_OUTPUT 10.0 10.0 200.0 % FLOAT 0..7 immediately 4.5.1 1.01
5464 Knee-point compensation pos. flow POS_DUAL_GAIN_COMP_FLOW 10.0 0.2 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5465 Knee-point compensation pos. voltage POS_DUAL_GAIN_COMP_VOLTAGE 10.0 0.2 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5466 Rounding range for knee-point compensation DUAL_GAIN_COMP_SMOOTH_RANGE 2.5 0.0 20.0 % FLOAT 0..7 immediately 4.5.1 1.01
5467 Knee-point compensation neg. flow NEG_DUAL_GAIN_COMP_FLOW 10.0 0.2 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5468 Knee-point compensation neg. voltage NEG_DUAL_GAIN_COMP_VOLTAGE 10.0 0.2 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5470 Offset compensation OFFSET_COMPENSATION 0 -4000 4000 - WORD immediately 4.5.1 1.01
5475 Manipulated voltage limitation negative OUTPUT_VOLTAGE_NEG_LIMIT 10.0 0.0 10.0 V FLOAT 0..7 immediately 4.5.3 1.01
5480 Knee-point compensation pos. flow in zero range POS_DUAL_GAIN_COMP_Z_FLOW 0.01 0.01 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5481 Knee-point compensation pos. volt. in zero range POS_DUAL_GAIN_COMP_Z_VOLT 0.0 0.0 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5482 Knee-point compensation rounding in zero range DUAL_GAIN_COMP_SMOOTH_Z_R 0.0 0.0 10.0 % FLOAT 0..7 immediately 4.5.1 1.01
5483 Knee-point compensation neg. flow in zero range NEG_DUAL_GAIN_COMP_Z_FLOW 0.01 0.01 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5484 Knee-point compensation neg. volt. in zero range NEG_DUAL_GAIN_COMP_Z_VOLT 0.0 0.0 95.0 % FLOAT 0..7 immediately 4.5.1 1.01
5485 Knee-point compensation pos. flow saturation POS_DUAL_GAIN_COMP_S_FLOW 100.0 0.2 100.0 % FLOAT 0..7 immediately 4.5.1 1.01
5486 Knee-point compensation pos. voltage saturation POS_DUAL_GAIN_COMP_S_VOLT 100.0 0.2 100.0 % FLOAT 0..7 immediately 4.5.1 1.01
5488 Knee-point compensation neg. voltage saturation NEG_DUAL_GAIN_COMP_S_VOLT 100.0 0.2 100.0 % FLOAT 0..7 immediately 4.5.1 1.01
5500 Number of velocity filters NUM_SPEED_FILTERS 0 0 1 - UNS.WORD 0...7 immediately 4.3.1 1.01
5501 Type of velocity filter SPEED_FILTER_TYPE 0 0 257 - UNS.WORD 0...7 immediately 4.3.1 1.01
5502 PT1 time constant for velocity filter 1 SPEED_FILTER_1_TIME 0.0 0.0 500.0 ms FLOAT 0...7 immediately 4.3.1 1.01
5506 PT2 natural frequency for velocity filter 1 SPEED_FILTER_1_FREQUENCY 2000.0 10.0 8000.0 Hz FLOAT 0...7 immediately 4.3.1 1.01
5507 PT2 damping for velocity filter 1 SPEED_FILTER_1_DAMPING 0.7 0.2 1.0 - FLOAT 0...7 immediately 4.3.1 1.01
5514 Band-stop filter blocking frequency for vel. filter 1 SPEED_FILTER_1_SUPPR_FREQ 3500.0 10.0 7999.0 Hz FLOAT 0...7 immediately 4.3.1 1.01
5515 Band-stop filter bandwidth for velocity filter 1 SPEED_FILTER_1_BANDWIDTH 500.0 5.0 7999.0 Hz FLOAT 0...7 immediately 4.3.1 1.01
5516 Numerator bandwidth for velocity filter 1 SPEED_FILTER_1_BW_NUMERATOR 0.0 0.0 7999.0 Hz FLOAT 0...7 immediately 4.3.1 1.01
4.15 Parameters table
4 Firmware Drive Functions
4-171
Attribute Firm-
MD no. Name in plaintext Name in NC Version Min. Max. Unit Data type Sec- ware-
Index Active
4-172
tion Version
5520 Band-stop filter natural frequency for vel. filter 1 SPEED_FILTER_1_BS_FREQ 100.0 1.0 141.0 % FLOAT 0...7 immediately 4.3.1 1.01
5522 Time constant for velocity actual value filter ACT_SPEED_FILTER_TIME 0 0 0 - FLOAT Power On - 1.01.08
5531 Manipulated variable enable delay OUTPUT_ENABLE_DELAY 300 0 500 ms UNS.WORD immediately 4.12 1.01
5532 Power enable delay time POWER_ENABLE_DELAY 100 0 300 ms UNS.WORD immediately 4.12 1.01
4.15 Parameters table
5550 Reference value of pressure sensor A at 10 V PRESSURE_SENS_A_REF 200.0 50.0 6000.0 bar FLOAT immediately 4.11 1.01
4 Firmware Drive Functions
5551 Offset adjustment for pressure sensor A PRESSURE_SENS_A_OFFS 0 -32760 32760 - WORD immediately 4.11 1.01
5552 Reference value of pressure sensor B at 10 V PRESSURE_SENS_B_REF 200.0 50.0 6000.0 bar FLOAT immediately 4.11 1.01
5553 Offset adjustment for pressure sensor B PRESSURE_SENS_B_OFFS 0 -32767 32767 - WORD immediately 4.11 1.01
5600 Concealable alarms (Power On) ALARM_MASK_POWER_ON 0 0 FFFF HEX UNS.WORD immediately 4.13 1.01
5601 Concealable alarms (Reset) ALARM_MASK_RESET 0 0 FFFF HEX UNS.WORD immediately 4.13 1.01
5605 Time for velocity controller at limit SPEEDCTRL_LIMIT_TIME 200.0 20.0 1000.0 ms FLOAT immediately 4.13 1.01
5606 Threshold for velocity controller at limit SPEEDCTRL_LIMIT_THRESHOLD 120000.0 0.0 120000.0 mm/min FLOAT immediately 4.13 1.01
5609 Max. measuring speed of linear scale ENC_SPEED_LIMIT 240000.0 1.0 240000.0 mm/min FLOAT immediately 4.13 1.01
5614 Valve spool monitoring timer VALVE_ERROR_TIME 50 1 100 ms UNS.WORD immediately 4.13 1.01
5620 Bits of variable signaling functions PROG_SIGNAL_FLAGS 0 0 7 HEX UNS.WORD immediately 4.13 1.01
5621 Signal number of variable signaling functions PROG_SIGNAL_NR 0 0 100 - UNS.WORD immediately 4.13 1.01
5622 Address to be monitored by variable sign. funct. PROG_SIGNAL_ADDRESS 0 0 FFFFFF HEX UNS.WORD immediately 4.13 1.01
5623 Threshold for variable signaling functions PROG_SIGNAL_THRESHOLD 0 0 FFFFFF HEX UNS.WORD immediately 4.13 1.01
5624 Hysteresis for variable signaling functions PROG_SIGNAL_HYSTERESIS 0 0 FFFFFF HEX UNS.WORD immediately 4.13 1.01
5625 Dropout delay for variable signaling function PROG_SIGNAL_ON_DELAY 0 0 10000 - UNS.WORD immediately 4.13 1.01
5626 Dropout delay for variable signaling function PROG_SIGNAL_OFF_DELAY 0 0 10000 - UNS.WORD immediately 4.13 1.01
5648 Valve identification parameter 1 VALVE_ID_PARAMS1 0 0 7999 - UNS.WORD immediately - 1.01.12
5650 Diagnostic control DIAGNOSIS_CONTROL_FLAGS 0 0 FFFF HEX UNS.WORD immediately 4.14 1.01
tion Version
5651 Signal number of min/max memory MINMAX_SIGNAL_NR 0 0 FFFF - UNS.WORD immediately 4.14 1.01
5652 Memory location of min/max memory MINMAX_ADDRESS 0 0 FFFFFF HEX UNS.WORD immediately 4.14 1.01
5653 Minimum value of min/max memory MINMAX_MIN_VALUE 0 0 FFFFFF HEX UNS.WORD immediately 4.14 1.01
5654 Maximum value of min/max memory MINMAX_MAX_VALUE 0 0 FFFFFF HEX UNS.WORD immediately 4.14 1.01
5655 Monitor memory location segment MONITOR_SEGMENT 0 0 FFFF HEX UNS.WORD immediately 4.14 1.01
5656 Monitor memory location address MONITOR_ADDRESS 0 0 FFFFFF HEX UNS.WORD immediately 4.14 1.01
5657 Monitor value display MONITOR_DISPLAY 0 0 FFFFFF HEX UNS.WORD immediately 4.14 1.01
5658 Monitor value input MONITOR_INPUT_VALUE 0 0 FFFFFF HEX UNS.WORD immediately 4.14 1.01
5704 Actual pressure A ACTUAL_PRESSURE_A 0.0 -10000.0 10000.0 bar FLOAT immediately 4.14 1.01
5705 Actual pressure B ACTUAL_PRESSURE_B 0.0 -10000.0 10000.0 bar FLOAT immediately 4.14 1.01
5706 Velocity setpoint DESIRED_SPEED 0.0 -240000.0 240000.0 mm/min FLOAT immediately 4.14 1.01
5707 Actual velocity value ACTUAL_SPEED 0.0 -240000.0 240000.0 mm/min FLOAT immediately 4.14 1.01
5708 Actual cylinder force ACTUAL_CYL_FORCE 0.0 -10000000.0 10000000.0 N FLOAT immediately 4.14 1.01
5709 Significance of voltage representation VOLTAGE_LSB 0.0 -100000.0 100000.0 V FLOAT immediately 4.14 1.01
5710 Significance of pressure representation PRESSURE_LSB 0.0 -240000.0 240000.0 bar FLOAT immediately 4.14 1.01
5711 Significance of velocity representation SPEED_LSB 0.0 -240000.0 240000.0 mm/min FLOAT immediately 4.14 1.01
5714 Significance of position representation POSITION_LSB 0.0 -1000000.0 1000000.0 nm FLOAT immediately 4.14 1.01
5715 Voltage for valve spool position setpoint DESIRED_VALVE_SPOOL_POS 0.0 -10.0 10.0 V FLOAT immediately 4.14 1.01
5716 Voltage for actual valve spool position ACTUAL_VALVE_SPOOL_POS 0.0 -10.0 10.0 V FLOAT immediately 4.14 1.01
5717 Cylinder force setpoint DESIRED_CYL_FORCE 0.0 -10000000.0 10000000.0 N FLOAT immediately 4.14 1.01
5720 CRC diagnostic parameter CRC_DIAGNOSIS 0 0 FFFF - UNS.WORD immediately 4.14 1.01
5725 Normalization of force setpoint interface MAX_FORCE_FROM_NC 0.0 0.0 10000000.0 N FLOAT immediately 4.14 1.01
5730 Operating mode display OPERATING_MODE 1 1 FFFF HEX UNS.WORD immediately 4.14 1.01
5731 Image ZK1_PO register CL1_PO_IMAGE 0 0 FFFF HEX UNS.WORD immediately 4.14 1.01
5732 Image ZK1_RES register CL1_RES-IMAGE 0 0 FFFF HEX UNS.WORD immediately 4.14 1.01
4.15 Parameters table
4 Firmware Drive Functions
4-173
Attribute Firm-
MD no. Name in plaintext Name in NC Version Min. Max. Unit Data type Sec- ware-
Index Active
4-174
tion Version
5735 Processor capacity utilization PROCESSOR_UTILIZATION 0 0 FFFF % UNS.WORD immediately 4.14 1.01
5740 Actual position in relation to machine zero ACTUAL_POSITION 0.0 -10000000.0 10000000.0 mm FLOAT immediately 4.14 1.01
5741 Piston position in relation to piston zero ACTUAL_PISTON_POSITION 0.0 -10000000.0 10000000.0 mm FLOAT immediately 4.14 1.01
5790 Measuring circuit type of measuring system ENC_TYPE 0 -1 32767 - WORD immediately 4.14 1.01
Measuring system
(encoder
connection)
Pressure sensor
Servo solenoid
valve
DACs
Drive bus
Device bus
Axis 1 Axis 2
F1900 F1901
Measuring One position encoder for each axis can be evaluated on the module.
systems
S X101: Axis 1
S X102: Axis 2
The measuring system must always be plugged into the connector of the asso-
ciated axis.
See Section 7.1 for further details.
Table 5-1 Connectors X101, X102; 15-pole male sub D connector (two-tier) in
each case
Table 5-2 Connectors X111, X112; 15-pin female sub D connector in each case
S X122: Axis 2
Table 5-3 Connectors X121, X122; both are 15-pin subminiature D female
connectors
The analog valve actual value inputs are differential with 100 kΩ input
resistance.
The current ratings of the 24 V outputs on the servo solenoid value are
Fuse The switched 24 V outputs for axes 1 and 2 are protected by miniature fuses;
fuse type F1900 for axis 1 and F1901 for axis 2.
Value: 2.5 AF/250 V; 5x20 mm UL
From: Wickmann-W erke GmbH
Annenstraße 113
58453 Witten
or
PO Box 2520
58415 Witten
Order No.: 194
5.1.4 Terminals
Shut-off valves (axis-specific), external 26.5 V supply, enabling, BERO inputs
S X431: Axis 1
S X432: Axis 2
Warning
! If the polarity of the 24 V supply is reversed, then the shut-off valves will open
immediately, even if the NC or closed-loop control is not in operation!
1) I=Input; O=Output
Note
Each of the shut-off valves must be connected directly via 2 leads to pins 2/3 of
X431 or X432!
A current-compensated interference suppression coil is inserted at the input for
the external incoming supply terminal P24, terminal M24 (pins 5 and 6 of
X431).
Terminal M24 and terminal MV1/MV2 must therefore not be reversed or
short-circuited.
The internal enabling voltage (terminal 9) is provided in order to supply the
BEROs and terminal 663, and must not be used to supply hydraulics
components. The hydraulics components must be supplied via incoming
supply P24. The voltages may not be connected in parallel.
Enabling inputs Module-specific enabling commands are issued by terminal 663. As no power
section is installed, no relay is available. The input is therefore evaluated via
optocouplers in the HLA module and also acts on the shut-off valves.
The enable voltage can be picked off at terminal 9.
Terminal 663 is referenced to the internal enabling voltage (ground, termi-
nal 19).
Test sockets The start-up tool or an MMC102/103 can be used to assign internal signals to
the test sockets on the 611D drive (in conjunction with SINUMERIK 840D),
where the signals are then available as analog values (see also Section 3.11).
DAC1 DAC2
DAC3 Ground
Functionality Three 8-bit digital/analog converter (DAC) channels are available on the 611D
hydraulics module. An analog image of various drive signals can be connected
through 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 set
to 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 user
info, e.g. 1V = 22.5A.
Bit 23 16 15 8 7 0 (LSB)
Activating the The display for activating and setting the parameters of the DAC outputs is
analog output called up from the basic machine display by pressing the Start-up /
Drive/Servo / Configur. DAC soft keys.
Use the Start soft key.to activate the configuration. Active DACs are identified
(active/inactive) on the left of the display. The output is ended with Stop (active/
inactive).
The selected signals are active after POWER ON.
Output voltage The DAC operates on a voltage of between 0 V and +5 V. The 2.5 V output volt-
range age corresponds to the zero point of the displayed signal. A two’s complement
is used in the digital/analog conversion, see Fig. 5-3.
UDAC
00Hex
2.5V
00Hex FFHex
0V
80Hex (1000 0000d)
Mains connection 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 a mains supply module as an ex-
tended power supply). No provision has been made for any other type of volt-
age supply and 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 SIMODRIVE
monitoring module!
X101
X102
X111
X112
X121
X122
X35 Bus terminator
X34
Drive bus
Device bus
SIEMENS
SIMODRIVE
5.3 Notes
Note
The following information refers to the electrical section of the HLA.
1) Current reduction above 40°C at the servo solenoid valve output, see Subsection 5.1.3.
Note
The following information refers to the electrical section of the HLA.
Function-impairing When working in areas where there is an unacceptably high dust hazard, the
dust control must be operated in a cabinet with a heat exchanger or in a cabinet with
a suitable air intake.
Notes
Sorting The alarms are listed in ascending order of alarm number. There are gaps in the
sequence.
Structure of alarm Each alarm, consisting of an alarm number and alarm text, is described with
description 4 categories:
S Explanation
S Response
S Remedy
S Program continuation.
Safety
Danger
! Please check the situation in the plant on the basis of the description of the
active alarm(s). Eliminate the causes for the occurrence of the alarms and
acknowledge in the manner indicated. Failure to observe this warning will place
your machine, workpiece, stored settings and possibly even your own safety at
risk.
300 000 to For a description of the alarms with error numbers 300 000 to 300 499,
please refer to documentation
300 499
References: /DA/, Diagnostics Guide
300 500 Axis %1, drive %2 system error, error codes %3, %4
Explanation %1 = NC axis number
%2 = drive number
%3 = error code 1
%4 = error code 2
The drive has signaled a system error. For an exact breakdown of error codes,
see /FBA/ DB1, Operational Messages/Alarm Responses.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Please inform the authorized personnel/service department.
Reinitialize the drive.
The search for the precise cause of error can only be performed by the develop-
ment team. The displayed error codes are always needed for this.
SIEMENS AG, After-Sales Support for A&D MC Products, Hotline.
Continue program Switch control system OFF and ON again.
300 504 Axis %1, drive %2 measuring circuit fault in motor measuring system
Explanation %1 = NC axis number
%2 = drive number
Signal level of motor encoder too small or noisy. SSI encoder: Parameter setting
error (bit 9 of MD 5027 Bit 9 not set)
Response Mode group not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC start disable.
NC stopped in response to alarm.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Please inform the authorized personnel/service department.
Check encoder, encoder leads and connectors between drive motor and 611D
module: check for temporary interruptions (loose contact) - e.g. caused by
movements in cable tow.
S Replace motor, encoder and/or cable if necessary
S Check shield bond to front plate of closed-loop plug-in module (top screw)
S Replace the control module.
S 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.).
Continue program Switch control system OFF and ON again.
300 508 Axis %1, drive %2 zero mark monitoring motor measuring system
Explanation %1 = NC axis number
%2 = drive number
Error in modulo (16/10) incrementation of encoder mark number on zero marker
crossings. Increments have been lost or extra increments trapped.
The alarm can be reconfigured using MD 11412:
ALARM_REACTION_CHAN_NOREADY (channel not ready).
Response Mode group not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
300 702 Axis %1, drive %2 drive basic clock cycle invalid
Explanation %1 = NC axis number
%2 = drive number
The drive basic clock cycle set on the NC is too high for the drive.
Response NC not ready.
Mode group not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy No remedial action is required. After the system has powered up again, 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 for
actual value sensing) are automatically altered so that the relevant limits are
applied.
Continue program Switch control system OFF and ON again.
300 707 Axis %1, drive %2 drive basic clock cycle axially unequal
Explanation %1 = NC axis number
%2 = drive number
The drive basic clock cycle is different for the two axes on a 2-axis module.
This alarm can only occur with OEM users who have the 611D drive without the
standard NCK interface. In this instance, it is possible to transfer different axial
drive clock cycles to the 611D modules.
300 710 Axis %1, drive %2 position controller clock cycle axially unequal
Explanation %1 = NC axis number
%2 = drive number
The position controller clock cycle is different for the two axes on a 2-axis
module.
This alarm can only occur with OEM users having the 611D drives without the
standard NCK interface. In this instance, it would be possible to transfer differ-
ent axial position controller clock cycles to the 611D module.
Response NC not ready.
Mode group not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Please inform the authorized personnel/service department.
Set the position controller cycle to the same value for both axes.
Continue program Switch control system OFF and ON again.
300 713 Axis %1, drive %2 lead time for position controller invalid
Explanation %1 = NC axis number
%2 = drive number
The position controller computing time reduction specified by the NC must be
shorter than the position controller cycle. The offset must be an integer multiple
of the speed controller cycle.
Response NC not ready.
Mode group not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Please inform the authorized personnel/service department.
MD 10082: CTROUT_LEAD_TIME (offset in setpoint transfer time).
Continue program Switch control system OFF and ON again.
300 754 Axis %1, drive %2 signal number var. signaling function invalid
Explanation %1 = NC axis number
%2 = drive number
The signal number for output of the appropriate signaling function is illegal. The
permissible signal number range starts at 0 and ends at 29.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Please inform the authorized personnel/service department.
Enter the correct signal number.
Continue program Clear alarm on all channels by pressing RESET. Restart part program.
Response Under certain circumstances it can be switched over across the entire channel
via MD.
NC not ready.
Mode group not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The newly calculated data must be saved (soft key: SAVE).
The new parameter settings become operative when the system is next booted!
Continue program Switch control system OFF and ON again.
300 854 Axis %1, drive %2 signal number var. signaling function invalid
Explanation %1 = NC axis number
%2 = drive number
The signal number for output of the appropriate signaling function is illegal. The
signal number range is between 0 and 29.
Response Alarm display
Interface signals are set
Remedy Enter the correct signal number.
Continue program Alarm display with cause of the alarm disappears. No further operator action
required.
310 505 Axis %1, drive %2 meas. circuit error abs. track, code %3
Explanation %1 = NC axis number
%2 = drive number
%3 = detailed error code
Absolute encoder (EQN 1325)
Monitoring of encoder hardware and EnDat or SSI interface.
- Error in SSI encoder parameters (MD 5028)
- SSI encoder: Fault in 24 V voltage supply
- SSI encoder: Break in data or clock pulse cable
More precise diagnosis via error code MD 5023: ENC_ABS_DIAGNOSIS_MO-
TOR (diagnosis of absolute track in motor meas. circuit):
1)
CRC error: Bits 7 and 13 Meaning:
0 1 CRC error from SIDA-ASIC
1 0 Check byte error
1 1 Error in correction of absolute track via
increment track
2) Bit 12 and Bit 15: Zero-level monitoring SSI
3) Bit 14 and Bit 15: Idle-level monitoring SSI
Response Mode group not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC start disable.
NC stopped in response to alarm.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Please inform the authorized personnel/service department.
S Check encoder, encoder leads and connectors between drive motor and
611D module: check for temporary interruptions (loose contact) - e.g.
caused by movements in cable tow.
310 702 Axis %1, drive %2 invalid position controller clock cycle
Explanation %1 = NC axis number
%2 = drive number
The monitoring function on the 611D module has detected a position controller
clock cycle that is not within the permissible tolerance range.
The general conditions for obtaining a permissible clock cycle are:
1. Minimum cycle period: 250 µs
2. Maximum pulse rate: 4 s
3. The position controller pulse rate must be a multiple of the speed controller
cycle given in the drive MD 5001: SPEEDCTRL_CYCLE_TIME.
Response NC not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Change the position controller clock cycle on the NC
Continue program Switch control system OFF and ON again.
310 704 Axis %1, drive %2 velocity controller clock cycle axially unequal
Explanation %1 = NC axis number
%2 = drive number
The speed controller cycle MD 5001: SPEEDCTRL_CYCLE_TIME must be
identical for both axes.
Response NC not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Set velocity controller clock cycle in MD 5001: SPEEDCTRL_CYCLE_TIME to
an identical value for both axes.
Continue program Switch control system OFF and ON again.
310 708 Axis %1, drive %2 no. of encoder marks motor measuring system invalid
Explanation %1 = NC axis number
%2 = drive number
The number of encoder marks of the motor measuring system in the drive
MD 5005: ENC_RESOL_MOTOR (no. of encoder marks motor measuring sys-
tem) is either zero or greater than the maximum input limit.
310 709 Axis %1, drive %2 error in piston diameter or piston rod diameter
Explanation %1 = NC axis number
%2 = drive number
The piston diameter 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 diameter
set 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 diameter
set in drive MD 5131: CYLINDER_PISTON_DIAMETER
Response NC not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Enter a valid piston diameter setting in drive MD 5131:
Enter CYLINDER_PISTON_DIAMETER (0 t D v 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.
Continue program Switch control system OFF and ON again.
310 750 Axis %1, drive %2 feedforward control gain too high
Explanation %1 = NC axis number
%2 = drive number
The feedforward control gain is calculated from the reciprocal of the controlled
system gain in drive MD 5435: CONTROLLED_SYSTEM_GAIN.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy
S Increase the speed controller cycle time in MD 5001:
SPEEDCTRL_CYCLE_TIME.
S Reduce the force controller feedforward factor in MD 5247:
FORCE_FFW_WEIGHT.
S Increase the controlled system gain setting in MD 5435: CON-
TROLLED_SYSTEM_GAIN.
Continue program Cancel alarm in all channels by pressing RESET. Restart part program.
310 751 Axis %1, drive %2 proportional gain of velocity controller too high
Explanation %1 = NC axis number
%2 = drive number
The P gain for the velocity controller is too high:
310 752 Axis %1, drive %2 I-action gain of velocity controller invalid
Explanation %1 = NC axis number
%2 = drive number
The integral gain in MD 5409: SPEEDCTRL_INTEGRATOR_TIME cannot be
represented.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Continue program Cancel alarm in all channels by pressing RESET. Restart part program.
310 754 Axis %1, drive %2 friction compensation gradient too high
Explanation %1 = NC axis number
%2 = drive number
Reduce the friction compensation gradient component MD 5460:
FRICTION_COMP_GRADIENT is too high.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Reduce the friction compensation gradient component MD 5460:
FRICTION_COMP_GRADIENT.
Continue program Cancel alarm in all channels by pressing RESET. Restart part program.
S select a lower setting for the negative area adaptation factor in MD 5463
AREA_FACTOR_NEG_OUTPUT.
Continue program Cancel alarm in all channels by pressing RESET. Restart part program.
310 756 Axis %1, drive %2 controlled-system gain is less than/equal to zero
Explanation %1 = NC axis number
%2 = drive number
The controlled system gain setting in drive MD 5435:
CONTROLLED_SYSTEM_GAIN is less than or equal to zero.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Enter a valid controlled system gain setting in drive MD 5435:
CONTROLLED_SYSTEM_GAIN (see drive model data calculation).
Continue program Cancel alarm in all channels by pressing RESET. Restart part program.
310 757 Axis %1, drive %2 blocking frequency > Shannon frequency
Explanation %1 = NC axis number
%2 = drive number
The bandstop frequency set for a velocity or control output filter is higher than
the Shannon sampling frequency defined by the sampling theorem.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
310 758 Axis %1, drive %2 natural frequency > Shannon frequency
Explanation %1 = NC axis number
%2 = drive number
The natural frequency of a velocity filter is higher than the Shannon sampling
frequency defined by the sampling theorem.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The natural frequency in Hz of a velocity must be less than the reciprocal of two
velocity controller clock cycles.
Speed filter:
MD 5520 * 0.01 * MD 5514 < 1 / ( 2 * MD 5001 * 31.25 microsec)
310 759 Axis%1, drive%2 numerator bandwidth exceeds double blocking fre-
quency
Explanation %1 = NC axis number
%2 = drive number
The numerator bandwidth of a velocity or control output filter is greater than 2x
the blocking frequency.
The error message is only generated for the general bandstop if the following
applies:
S Speed filter 1:
MD 5516 > 0.0 or
MD 5520 <> 100.0
S Control output filter 1 in velocity controller:
MD 5212 > 0.0
S Control output filter 2 in velocity controller:
MD 5215 > 0.0
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The numerator bandwidth must be less than twice the blocking frequency.
S Speed filter 1:
- BSF bandwidth numerator drive MD 5516:
SPEED_FILTER_1_BW_NUMERATOR
- BSP blocking frequency drive MD 5514:
SPEED_FILTER_1_SUPPR_FREQ
MD 5516 v 2 * MD 5514
MD 5212 v 2 * MD 5210
MD 5215 v 2 * MD 5213
Continue program Cancel alarm on all channels by pressing RESET. Restart part program.
310 760 Axis %1, drive %2 denominator bandwidth exceeds double natural fre-
quency
Explanation %1 = NC axis number
%2 = drive number
The denominator bandwidth of a velocity filter is greater than 2x the natural
frequency.
The error message is only generated for the general bandstop if the following
applies:
Speed filter 1:
MD 5516 > 0.0 or
MD 5520 <> 100.0
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The denominator bandwidth of a velocity filter must be less than twice the natu-
ral frequency.
Speed filter 1:
310 761 Axis %1, drive %2 proportional gain of force controller too high
Explanation %1 = NC axis number
%2 = drive number
The P gain of the force controller in MD 5242: FORCECTRL_GAIN is too high.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Enter a lower value for the force controller P gain in MD 5242:
FORCECTRL_GAING.
Continue program Cancel alarm on all channels by pressing RESET. Restart part program.
310 762 Axis %1, drive %2 I-action gain of force controller invalid
Explanation %1 = NC axis number
%2 = drive number
The integral gain in MD 5244: FORCECTRL_INTEGRATOR_TIME cannot be
represented.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Continue program Cancel alarm on all channels by pressing RESET. Restart part program.
310 764 Axis %1, drive %2 force controller controlled-system gain is less than/
equal to zero
Explanation %1 = NC axis number
%2 = drive number
The controlled-system gain setting for the force controller in drive MD 5240
FORCECONTROLLED_SYSTEM_GAIN is less than or equal to zero.
Response NC not ready.
Under certain circ. it can be switched over across the entire channel via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy Enter a valid controlled-system gain setting in drive MD 5240
FORCECONTROLLED_SYSTEM_GAIN (see Calculate Model Data).
Continue program Cancel alarm on all channels by pressing RESET. Restart part program.
310 771 Axis %1, drive %2 gradient in fine range of valve characteristic is less
than/equal to zero
Explanation %1 = NC axis number
%2 = drive number
The gradient in the fine area of the valve characteristic is less than or equal to
zero.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The gradient in the fine area is calculated as follows:
310 772 Axis %1, drive %2 gradient in coarse range of valve characteristic is less
than/equal to zero
Explanation %1 = NC axis number
%2 = drive number
The gradient in the coarse area of the valve characteristic is less than or equal
to zero.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The gradient in the coarse range is calculated according to the:
310 773 Axis %1, drive %2 gradient at end of saturation range of valve characteris-
tic is less than/equal to zero
Explanation %1 = NC axis number
%2 = drive number
The gradient at the end of the saturation range of the valve characteristic is less
than/equal to zero. The saturation range is rounded by a parabola function. The
parabola has a maximum in the saturation region and therefore cannot be
inverted.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The gradient at the end of the saturation region is calculated according to the:
310 774 Axis %1, drive %2 overlap between zero and breakpoint ranges of valve
characteristic
Explanation %1 = NC axis number
%2 = drive number
The zero range and breakpoint range of the valve characteristic are overlap-
ping.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The zero and breakpoint ranges overlap if:
310 775 Axis %1, drive %2 overlap between breakpoint range and saturation re-
gion of valve characteristic
Explanation %1 = NC axis number
%2 = drive number
The breakpoint range and saturation region of the valve characteristic are over-
lapping.
Response NC not ready.
Under certain circumstances it can be switched over across the entire channel
via MD.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
The NC switches to follow-up mode.
Alarm display.
Interface signals are set.
Remedy The breakpoint range and saturation region overlap if:
311 710 Axis %1, drive %2 resolution invalid for SSI motor measuring system
Explanation %1 = NC axis number
%2 = drive number
The motor measuring system is incorrectly configured for an SSI encoder:
MD 5022 ENC_ABS_RESOL_MOTOR must not be zero.
Response NC not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
Alarm display.
Interface signals are set.
Remedy Set MD 5022 to the correct value
Rotary encoder: Single-turn resolution (increments per revolution)
Linear encoder: Resolution of one increment (in nanometers)
Continue program Switch control system OFF and ON again.
311 711 Axis %1, drive %2 message frame length invalid for SSI motor measuring
system
Explanation %1 = NC axis number
%2 = drive number
The motor measuring system is incorrectly configured for an SSI encoder.
Response Mode group not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
Alarm display.
Interface signals are set.
Remedy Check the following MD and correct if necessary
MD 5028
MD 5021 (Multi-turn): Number of resolvable revolutions
MD 5022 (Single-turn): Number of increments per revolution
MD 5027 Bit 12: Parity bit
MD 5027 Bit 14 Alarm bit
Example:
SSI encoder with 25-bit long message frame, 12 bits multi-turn, 12 bits single-
turn, 1 alarm bit, no parity bit:
MD 5028 = 25
MD 5021 = 4096
MD 5028= 4096
MD 5027 bit 12 = 0
MD 5027 bit 14 = 1
Continue program Switch control system OFF and ON again.
311 712 Axis %1, drive %2 Invalid multi-turn SSI motor measuring system
Explanation %1 = NC axis number
%2 = drive number
The motor measuring system is incorrectly configured for a linear SSI motor
measuring system. A linear measuring system cannot have any multiturn infor-
mation.
Response Mode group not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
Alarm display.
Interface signals are set.
Remedy Set MD 5021 to 0.
Continue program Switch control system OFF and ON again.
311 716 Axis %1 drive %2 SSI measuring system not possible without incremental
signals
Explanation %1 = NC axis number
%2 = drive number
SSI encoders without incremental signals cannot be used with the existing
module.
Response Mode group not ready.
Channel not ready.
NC stopped in response to alarm.
NC start disable.
Alarm display.
Interface signals are set.
Remedy Use a new module (order no.: 6SN1115-0BA1 1-0AA1)
Continue program Switch control system OFF and ON again.
Note
For connector assignments, see Subsection 5.1.1.
Signal
voltages
Track signal A
UM(A)
Track signal *A
0 Mech. angle ϕ
Differential signal (A - *A)
Signal
voltages
Track signal B
UM(B) Track signal *B
0 Mech. angle ϕ
0 Mech. angle ϕ
Fig. 7-1 Required signal chart of measuring system signals for data definition
0 Mech. angle ϕ
45 degrees
0
Mech. angle ϕ
Differential signal (R - *R)
Uniqueness range
Direct component
UG(R) Useful signal
0 Mech. angle ϕ
α1 α2
Fig. 7-2 Required signal chart of measuring system signals (incremental and
reference) after differential amplification for data function
Ǹ U12+U22+...Un2
1) Definition for harmonic distortion: k = U0: Fundamental component
Ǹ U02+U12+...Un2 U1...Un: Harmonic components
Note
If signals which do not conform to this specification are used, problems such as
speed ripple, positioning inaccuracy or other malfunctions may be
encountered.
Connection
options
Direct linear
X101/X102 incremental
Adapter cable1) measuring system
310 128 LS 186
Linear
Adapter cable1) absolute
measuring system
SSI
Fig. 7-3 Example showing connection options for measuring system cable
Z 2:1
Length according to length code
Cen. 8 9 1
7 12 10 2
6 11 3
5 4
2
3
1 3
O 0,38 ye Ua1
3 5
*A 0,38 gn *Ua1
4 6
B 0,38 bk Ua2
6 8
*B 0,38 bn *Ua2
7 1
R 0,38 bu Ua0 3
10
*R 0,38 vt *Ua0
12 4
Trig/Uas 0,38 rd
14 7
Trig 0,38 or
15 9
5V sense 0,5 wh-rd 5V sense
9 2
P encoder 0,5 wh-bk 5V_encoder
1 12
0V sense 0,5 wh-bu 0V sense
11 11
M encoder 0,5 wh-ye M_encoder
2 10
Housing Housing
Item Meaning
Fig. 7-4 Measuring system lead for encoder with voltage signals (X101/X102)
Z 2:1
Length according to length code
Cen. 1 11 10
2 13 1216 9
17
3 14 15
8
4 7
5 6
2
3
1 3
O 0,14 ye Ua1
3 15
*A 0,14 gn *Ua1
4 16
6 B 0,14 bk Ua2
12
*B 0,14 bn *Ua2
7 13
Item Meaning
Fig. 7-5 Measuring system lead for encoder with voltage signals + EnDat (X101/X102)
Note
The BERO cable must be shielded.
1) I: Input, O: Output
Note
For connector assignments, see Subsection 5.1.2.
General The task of pressure sensors is to convert the mechanical “pressure” variable
into the electrical “voltage” or “current” variable.
The pressure sensors from the Bosch Rexroth product range are suitable for
pressure monitoring and control applications in mechanical engineering, injec-
tion molding machines, presses and many other areas.
The most important features of the sensors are
Note
Pressure sensor cables with pre-assembled sensor end are not available. The
following cable information is intended only as an example.
Instructions for
use
S Sensor must be mounted in vertical position with connector pointing down-
wards.
Selection of Sensors with a signal voltage of U=0...10 V are available in the following vari-
pressure sensor ants for the HLA module:
(recommended
types)
Dimensions/termin
al assignments
71.5- 2
G1/4”ISO 228 A
SW 32
Tightening torque 0.3 - 0.4 Nm
=20+5 Nm
12"1
O 18.8
O 35
Rexroth
Bosch
11"1
4
2 3 Ref. 0 V (signal)
3
P Usig
2
U 0V
4 1 1
Supply
Fig. 7-7 Rexroth pressure sensors, order nos. 0811 405 540, 0811 405 547 and 0811 405 554
G1/4”ISO 228 A
SW 32
=20+5 Nm
12"1
O 18.8
ÂÂ
Â
Â
ÂÂ
O 34
Rexroth
Bosch
Â
ÂÂ
11"1
1
Supply
2
P 0V
3
U Usig
4
Ref. 0 V (signal)
5
6
7
Fig. 7-8 Rexroth pressure sensors, order nos. 0811 405 531 and 0811 405 532
7-pin
Characteristics
Table 7-4 Characteristics of pressure sensors
Accessories A 4-pin square connector is supplied with the following pressure sensors with
order nos.: 0811 405 540
0811 405 547
0811 405 554.
For replacement purposes, it can be ordered under order no.: 1 834 484 061 or
1 834 484 063 from Bosch Rexroth AG.
Note
The following cable data for hydraulic systems is tailored specifically to Bosch
Rexroth products. If hydraulics components supplied by other manufacturers
are used, the pin assignments of the hydraulic-end connections might be
different!
2 3
1
3
O
M24EXT 0,18 bk Uext. 0 V
5 2
P24DS 0,18 bn Uext. 24 V
2 PIST1AP 0,18 rd Actual value, 0...10 V 1
15 PIST1AN 0,18 or Actual value, ground 3
14 4
Shield
1)
3
B
M24EXT 0,18 bk Uext. 0 V
9 2
P24DS 0,18 bn Uext. 24 V
1 PIST1BP 0,18 rd Actual value, 0...10 V 1
12 or 3
PIST1BN 0,18 Actual value, ground
11 4
Shield
Housing 1)
3 Male connector
S 4-pin socket included with pressure sensor
Bosch Rexroth order no.: 1 834 484 061 or 1 834 484 063
S 7-pin socket not included with pressure sensor
Bosch Rexroth order no.: 1 834 484 141
Order No. (MLFB) of signal lead for pressure sensors: 6FX2002-2AD00-1 VVV
Note
The following cable data for hydraulic systems is designed for directly and pilot
actuated Bosch Rexroth servo solenoid valves (see Subsection 2.3.2).
Pin 1 Z 2:1
Length according to length code
Note: Max. approved system cable length 40 m
Cen.
O
B F
C I
D
2 3
1
3
Item Meaning
Order No. (MLFB) of signal lead for 7-pin servo solenoid valve: 6FX2002-2BA00-1 VVV
Fig. 7-11 7-pin signal lead for servo solenoid valve (X121/X122) - standard version
Note
The pin assignments on valves supplied by other manufacturers may deviate
from the assignments shown in Fig. 7-11. Cables must be assembled by the
customer!
Pin 1 Z 2:1
Length according to length code
Note: Max. approved system cable length 40 m
Cen.
O
B F
C I
D
2 3
1
3
Item Meaning
Fig. 7-12 Interconnection diagram for 7-pin servo solenoid valve (X121/X122) - connection option 2 (customized)
Note
The following cable data for hydraulic systems is designed for directly and pilot
actuated Bosch Rexroth HR servo solenoid valves (see Subsection 2.3.2).
2 3
1
3
Item Meaning
Order No. (MLFB) of signal lead for 12-pin HR servo solenoid valve: 6FX2002-2BA10-1 VVV
Fig. 7-13 12-pin signal lead for HR servo solenoid valve (X121/X122)
Note
The following data for the connectors on the servo solenoid or HR servo
solenoid valve signal leads only applies to spare parts orders or where the
cables are to be made up by the customer. The cables are normally supplied
fully pre-assembled by Siemens.
O
B F
C I
D
X10 2.6
28.6 66
3 7 4
2
1 6
21.5 Approx. 66
5 4
6
10 3
7 11 9
2
8 1
29 79
Notes
Note
Neither company bears sole responsibility for the overall installation.
Siemens and Bosch Rexroth shall not be responsible unless they have actually
supplied the components listed in Table 8-1 or have explicitly certified that
components supplied by other manufacturers are compatible with the system.
Internet address
Up-to-date information about the products can be found on the Internet at the
following address:
http://www.siemens.com
Internet address
Up-to-date information about the products can be found on the Internet at the
following address:
http://www.boschrexroth.de
J
A.1.1 General
The servo solenoid valve is the final control element in the electro-hydraulic
control loop. It converts the electrical manipulated variable U=-10...+10 V into
the hydraulic variables pressure p and flow rate Q, and thus into a cylinder
movement.
Sliding spool These valves are of the sliding-spool type. A valve spool with 4 control edges
principle moves inside a steel sleeve, the control bore of which is connected to the
4 ports in the valve casing. The main stages of pilot-controlled valves do not
typically have the steel sleeve, in which case the control geometry is repre-
sented directly by the valve casing.
The ports in the valve casing are:
O B
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ Casing
ÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎ ÎÎÎÎ
ÎÎÎÎÎÎÎÎÎ
ÎÎ
ÎÎÎÎÎ
ÎÎÎ Steel sleeve
ÎÎÎ
ÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎ
ÎÎÎ
Valve spool
ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
T P
Solenoid actuation On size 6 and 10 standard servo solenoid valves, the valve spool is actuated
with valve spool directly by a stepless actuating solenoid. This converts a current I into a force F,
position control which is compared to the force of the reset spring. This comparison of forces
finally produces a travel s, and thus an opening cross-section at the control
edges of the valve spool.
To compensate for disturbance forces acting on the valve spool (flow forces)
and to reduce the hysteresis and response sensitivity or range of inversion, the
position of the armature, and therefore the spool travel, is scanned and applied
to a position control loop as an actual value. Any deviations from the spool posi-
tion setpoint are thus continuously corrected. This method is particularly suc-
cessful in reducing the valves’ sensitivity to dirt.
Very small control deviations, such as those caused when the valve spool
sticks, can be corrected by mobilizing the entire available magnetic force.
A wear-resistant, proximity-type differential transformer (LVDT) is used as the
spool travel sensor.
Valve amplifier
UE
FM
ÉÉ
FF Valve spool
ÉÉ
ÉÉ
U
S
FF
FM
Graphical symbol The operating principle of the servo solenoid valve is represented by a symbol
in the hydraulic circuit diagram. The symbol comprises a series of different
boxes denoting the valve positions.
The three stepless-transition valve positions are represented by additional lines.
The symbol also indicates how the valve is actuated. In this case, by direct sole-
noid actuation with spring return at one end.
If the valve has a fail-safe position, then the valve spool moves into a fourth
(safety) position when the valve is not powered. There are two alternative posi-
tions.
The symbol also illustrates the principle of position control applied to the valve
spool.
P T
Setpoint
Valve amplifier UE=0..."10 V
with position
control
O B O B
P T P T
Zero overlap in A continuous valve must have zero overlap around its mid-position if it is to be
mid-position used in a position control loop.
A positive overlap will be perceived negatively in the form of a dead zone of the
final control element.
In contrast, a negative overlap results in a marked increase in oil leakage.
To achieve zero overlap, valve spools, spool housings and spool sleeves must
be manufactured with extreme precision and made of wear-resistant materials.
The production costs incurred are correspondingly high.
To maintain the zero overlap over prolonged operating periods, it is essential to
ensure that a clean pressure medium is used (to prevent erosion of control
edges).
Q Q Q
U U U
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
O
ÎÎÎ B O B
ÎÎÎ
ÎÎÎÎ
ÎÎÎ O B
ÎÎÎÎ
ÎÎ ÎÎÎ
ÎÎÎ ÎÎÎ
ÎÎÎÎÎÎ ÎÎÎ
ÎÎ ÎÎÎ
ÎÎÎÎ ÎÎÎ
ÎÎÎÎ ÎÎÎ
Î ÎÎÎÎ
ÎÎÎ ÎÎÎ
ÎÎÎ
ÎÎ
ÎÎ ÎÎÎ
ÎÎÎÎÎÎ ÎÎ
ÎÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ
ÎÎ
ÎÎÎÎÎÎÎÎÎ
T ÎÎÎÎÎÎÎÎÎÎÎÎ
P
Ü=-
T T P
Ü=0
T ÎÎÎÎÎÎÎ
T ÎÎ P
Ü=+
T
Pressure The quality of zero overlap in the mid-position is represented by the pressure
intensification intensification characteristic.
This states what percentage of the control spool deflection from the hydraulic
zero point is needed to achieve a pressure differential of 80% system pressure
at the closed load ports. The values of this characteristic are typically in the
1...3% range.
The following graphical representation of the measurement, which covers all 4
control edges, shows this clearly.
∆p
∆p/ppu [%]
80
pA pB 60
40
20
O B -U E[%] U/Unom [%]
3 2 1 1 2 3
20
40
p 60
pPU
80
Flow The stepless spool movement, and thus the change in throttle cross-section at
characteristic, the control edges, results in a corresponding flowrate, which is represented as a
linear function of the spool travel s or of the electrical input signal U (manipulated vari-
able). The flow is dependent on the on the pressure drop, in addition to the
opening cross-section,
QX Ǹ Dp
Flow rate Q
P O
B T
O B
P T
O B Spool travel s
Input signal U
P T
P B After
O T
Q
Window in spool sleeve
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ U
Spool stroke
Flow Valves with a knee-shaped flow characteristic give the drive greater manipu-
characteristic, lated variable resolution in the lower signal range (better processing quality)
with knee and, at the same time, offer sufficient flow rate in the upper range (high rapid
traverse velocity).
Q/Qnom
Rapid traverse
10%
U/Unom
40%
Machining velocity
ÎÎÎÎÎÎÎ
Q/Qnom
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
10 %
ÎÎÎÎÎÎÎ 40 % U/UUnom
Spool stroke
Fig. A-9 Stepped control window in spool sleeve, example 40% - knee
Linearization of The knee-shaped characteristic of the valve is linearized in the HLA module to
knee-shaped flow match it to the closed-loop control of the overall drive (cylinder). No steady-state
characteristic operating point should be defined in the knee-point area.
The corresponding valve data are stored in the HLA module and automatically
parameterized when the order number is entered.
Q/Qnom
Valve characteristic
Linearized characteristic
10%
U/Unom
40%
compensation
Nominal flowrate This expresses the flow rate with fully opened valve in relation to a specific
pressure drop per control edge.
Typical nominal flow rate for directly-controlled servo solenoid valves (nominal
pressure drop of 35 bar per control edge):
S Size 6: Q=4...40 l/min
S Size 10: Q=50...100 l/min
Typical nominal flow rate for pilot-controlled servo solenoid valves (nominal
pressure drop of 5 bar per control edge):
S Size 10: Q=55...85 l/min
S Size 16: Q=120...200 l/min
The flow under other pressure conditions is calculated according to the law of
flow by the following formula:
∆pX
QX=Qnom @
∆pnom
I [dB]
O ϕ [°]
2 5%
0
-2 100
at -3 dB
-4
-6 -180
-8 -160
-10 Signal 100 Umax -140
-120
Signal 5% Umax
-100
at -90°
-80
-60
-40
-20
-0
10 20 40 60 80100 200 300 f [Hz]
Q
Q Q
U U U
Fig. A-12 Hysteresis, response sensitivity and range of inversion of servo solenoid valve
Filtration grade To maximize the service life of the control edges, thus ensuring the quality of
zero overlap, a degree of purity of the hydraulic medium (fluid) must be main-
tained.
The objective is contamination class 7...9 to NAS 1638. This can normally be
achieved with a pressure filter β10=75.
Mechanical The standard series of Bosch Rexroth size 6 and 10 servo solenoid valves
structure shown in the following diagram are based on the same principle.
The valve spool in its steel sleeve is pushed against the reset spring directly by
the actuating solenoid. The armature axis of the solenoid is mechanically
coupled 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) is
bolted 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 by
about 50%. When the power supply is switched off, it assumes a 4th position,
known as the fail-safe position. On connection and disconnection of the supply,
it slides through the crossed position.
The valves are available with a variety of nominal flow rates and two different
fail-safe positions.
Size 6 Size 10
P T
Fail-safe closed
O B
P T
Valve amplifier The functions of the integral valve amplifier are implemented with analog cir-
cuits, and are illustrated in the block diagram (see Fig. A-14).
The main amplifier functions are:
2.5 AF
+24 V=
O 0V Supply
+U B
B
+15 V DC 0V Reference point
C
-15 V Actual valve spool
DC D value
100k
100k
I Setpoint 0... +
- 10 V
F
10k Sign. Actual valve spool
value
Logic Protective
conductor
Shield
+U B
+
PID
-
S
U
Fig. A-14 Valve amplifier block diagram for directly-controlled servo solenoid valves, sizes 6 and 10 (Rexroth)
The principle of pilot control is applied in order to control higher flow rates.
Mechanical A size 10 or 16 directional control valve with suitable control edges is used as
structure the main stage on the valve spool. Like the piston rod of a cylinder, this stage is
hydraulically clamped and positioned by a size 6 pilot valve
(see Subsection A.1.2).
The position of the main spool is scanned by another position sensor and the
corresponding actual value applied to a second, subordinate position control
loop.
Inlet and outlet of The control fluid can be supplied and removed either internally via ports P and T
hydraulic fluid or, as often is the case in practice, externally via additional ports X and Y. The
unit is converted using suitable plugs.
Valve positions Pilot-actuated servo solenoid valves have only three stepless-transition valve
positions.
The 4th fail-safe position is omitted. If the supply voltage is disconnected, the
spring force of the main spool causes the valve to assume an indifferent mid-
position.
Valve amplifier The integral valve amplifier is mounted on the pilot valve assembly and contains
both position control loops. A cable is used to connect the position sensor on
the main stage to the amplifier.
X Y
P T
O B
Fig. A-15 Directly-controlled servo solenoid valves, sizes 10 and 16 example of an external control fluid port (Rexroth)
Fig. A-16
2.5 AF
O +24 V=
+U B
B 0V Supply
+15 V DC C 0V Reference point 1)
-15 V
DC D Actual valve spool
100k value +
I Setpoint 0... - 10 V
Diff. 100k
amp.
F Sign. Actual valve spool
10k value
Protective
conductor
Logic
Shield
S
U
Valve amplifier block diagram for pilot-controlled servo solenoid valves, sizes 10 and 16 (Rexroth)
A.1 Servo solenoid valves
A Hydraulics
A-251
A Hydraulics 10.03
A.1 Servo solenoid valves
General The HR (High Response) series of servo solenoid valves from Bosch
Rexroth offers particularly good dynamic and static characteristics, making it the
ideal addition to the range for highly sophisticated applications.
At the heart of the series is the 4WRREH 6 valve. This is also used as a pilot
valve in type 4WRVE pilot-controlled HR servo solenoid valves.
Both valve stages on pilot-actuated valves operate under position control.
Features In contrast to the other valves, the HR servo solenoid valve has the following
features:
12-pin connector
O B
Valve amplifier
P T
Fig. A-18
2.5 AF
+24 V=
0V Output stage supply
1 24 V
+U B
2 enabling of
3
4 Setpoint 0...+
- 10 V
100k
5
Logic 100k Sign.
6
10k 0V Actual valve spool value
7
+15 V DC 8 24 V
A-253
A Hydraulics 10.03
A.2 Cylinder
A.2 Cylinder
General The cylinder acts as the drive element in the electro-hydraulic control loop.
It converts the flowrate into rectilinear motion. In this case, high velocities are
required for rapid traverse movements as well as slow velocities for machining
operations
Through-rod or On a through-rod cylinder, a piston rod of the same diameter is mounted at both
differential ends as a power transmission element. Consequently, the piston areas at the
cylinder A and B ends are identical. Likewise, at a constant piston speed, the incoming
flow is equal to the displaced flow in the settled state. The through-rod cylinder
acts symmetrically both when traveling in and when traveling out.
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 have
different diameters. In the latter case, the piston areas at the A and B ends are
different. Furthermore, at a constant piston speed, the displaced flow is not the
same as the incoming flow. The maximum piston travel-in and travel-out speeds
are not the same on a differential cylinder (see Section 4.7).
This asymmetry can, however, be compensated by means of the piston area
adaptation function (MD 5112: VALVE_FLOW_FACTOR_A_B) on the HLA mod-
ule.
Apart from the piston diameter, it is necessary to specify the rod diameters at
the 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 stroke
and cylinder dead volume are also required.
D2 D0 D1
Through-rod cylinder
D1=D2
O B
D0 D1
Differential cylinder
O B
D2 D0 D1
D10D2
O B
Quality of seals The quality of the seals and guides on the piston, and the piston rod itself, must
be particularly high in order to minimize the friction.
Transitions from static to sliding friction have a particularly adverse affect on the
quality of control accuracy. A friction compensation setting has been provided in
the HLA module (MD 5460: FRICTION_COMP_RADIENT).
ÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌ
Ì ÌÌ
ÌÌÌ Ì ÌÌ
Ì
ÌÌ
ÌÌÌ ÌÌ
Ì
ÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌ ÌÌÌ Ì ÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌ ÌÌ
Piston rod
Piston
2 x guide ring
(PTFE)
ÌÌ
ÌÌ Ì
ÌÌ
ÌÌÌ ÌÌÌÌÌÌ
2 x guide ring Stabilizing ring
Seal (PTFE) (FPM)
(FPM+PTFE)
2 x sealing ring
(FPM+PTFE)
Dead volume The dead volume is the volume between the cylinder and servo solenoid valve
that is not displaced by one piston stroke. It reduces the natural frequency of
the drive and should be avoided wherever possible.
Cylinder pipework should be kept as short as possible, i.e. the servo solenoid
valve should be mounted directly on the cylinder.
The dead volume is set in the HLA module (MD 5135, MD 5136 and
MD 5141...5143).
J
Notes
MD Machine Data
MMC Human Machine Communication
MON Monitoring
MPI Multi-Point Interface
MS Mains Supply
MSD Main Spindle Drive
NC Numerical Control
NCU Numerical Control Unit
NMI Non-Maskable Interrupt
O Cylinder working port
OBE On-Board Electronics
OP Operator Panel
OPI Operator Panel Interface
Order No. Machine-Readable Product Designation (order no.)
P Pressure port (inlet), servo solenoid valve
P24EXTIN Input for +24 V external
P bus I/O (peripheral) bus
PBL Parameter Basic List
PCL Position Control Loop
PCMCIA Personal Computer Memory Card International Association
PER I/O (peripheral) module
PG Programming device
PI Program Invocation
PID Controller with Proportional, Integral and Differential components
PLC Programmable Logic Control
PS Power Supply (SIMATIC S7-300)
SC Status Class
SCI Serial Communication Interface
SL Servo Loop
SLM Synchronous Linear Motor (drive configuration)
SM SIMATIC S7-300 Signal Module, e.g. I/O modules
SRM (FDD) Synchronous Rotary Motor (drive configuration)
SW Software
T Tank port (return), servo solenoid valve
Term. Terminal
UI Unstabilized power supply
VCL Velocity control loop
VGA Video graphics adapter
h Cylinder stroke
pp Pump pressure
General Documentation
/ST7/ SIMATIC
Products for Totally Integrated Automation and Micro Automation
Catalog ST 70
Order No.: E86060-K4670-A111-A8-7600
/Z/ MOTION-CONNECT
Cable, Connectors & System Components for SIMATIC, SINUMERIK,
Masterdrives and SIMOTION
Catalog NC Z
Order No.: E86060-K4490-A001-B1-7600
Electronic Documentation
User Documentation
Manufacturer/Service Documentation
a) Lists
b) Hardware
Please enter the ID No.: 15257461 in the ’Search’ field (top right) and click on
“go”.
/GHA/ SINUMERIK/SIMOTION
ADI4 - Analog Drive Interface for 4 Axes (09.03 Edition)
Manual
Order No.: 6FC5297-0BA01-0BP1
c) Software
D2 Interactive Programming
F1 Travel to Fixed Stop
G2 Velocities, Setpoint/Actual Value Systems, Closed-Loop
Control
H2 Output of Auxiliary Functions to PLC
K1 Mode Group, Channel, Program Operation Mode
K2 Axes, Coordinate Systems, Frames, Actual Value System for
Workpiece, External Zero Offset
K4 Communication
N2 EMERGENCY STOP
P1 Transverse Axes
P3 Basic PLC Program
R1 Reference Point Approach
S1 Spindles
V1 Feeds
W1 Tool Offset
d) Installation and
Start-Up
Metal cabinet
Operator panel
Machine
control panel
611D
Fil- 840D
with Actual pressure
ter
HLA
*) Actual position
**) *)
Fil-
ter
Throttle
Supply terminal
Setpoint
*) On I/RF module
**)On OI module
Hydraulic valve control
S All components which are designated in the Ordering Information as approved for operation in a
combined SINUMERIK 840D/SIMODRIVE 611D installation comply with Directive 89/336/EEC
when operated in an installation of this type.
Note:
The sketch of the system configuration shows only the basic measures required to ensure that a typical system
configuration conforms to directive 89/336/EEC.
In addition, and especially if the system configuration deviates from this typical model, the installation guidelines for
EMC-compliant system design in the product documentation and the EMC design guidelines for SINUMERIK,
SIROTEC and SIMODRIVE
(order no.: 6FC5297-0AD30-0BP0) must be carefully observed and implemented.
C: Conformity of the products with Council Directive 89/336/EEC has been verified
by 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.
Control direction F
Determine control direction, 3-62
General, 3-62 Fault responses., 6-189
Limitation of manipulated voltage, 3-62 File functions
Control output, velocity controller, 4-111 Load data, 3-75
Controller adaptation Save data, 3-75
General, 3-73 Filter
Implementation, 3-73 Control output filter in velocity controller, 4-111
controller D component, 4-110 Velocity setpoint filter, 4-100
Controller data/calculate drive model data, 3-61 Fine adjustment and optimization, 3-62
Controller optimization, 3-61 Force controller
D response, 3-71 controller D component, 4-121
General, 3-68 controller P component, 4-120
I response, 3-72 Feedforward control filter, 4-122
P response, 3-71 Feedforward control gain, 4-119
controller P component, 4-108 I component, 4-121
Cylinder Servo gain, 4-120
Construction, 1-19 Function generator, 3-84
Dead volume, A-255 Position setpoint, 3-87
Differential cylinder, A-254 Signal types, 3-84
General, A-254 Signals, 3-84
Quality criteria, 1-19 Start-up of force controller, 4-115
Quality of seals, A-255 Valve spool setpoint, 3-85
Through-rod cylinder, A-254 Velocity setpoint, 3-86
Cylinder data, 4-136
Cylinder drive, Cylinder data, 4-136
Cylinder selection, 3-56 G
Cylinder pipes, 2-31
Grounding concept, 2-48
Friction, 2-31
Mounting, 2-31
Mounting position, 2-31
Piston diameter, 2-30 H
Position measuring system, 2-31
HLA machine data, 4-165
Rod diameter, 2-30
Hotline, 8-238
Seal, 2-31
Hydraulic power unit, 1-20
Stroke length, 2-30
Configuration, 2-43
Cooling:, 2-44
Drive power, 2-43
D Filtration, 2-43
flow rate, 2-43
DAC assignment, 5-182
Pressure, 2-43
DAC parameter settings, 3-89
Pump type, 2-43
DAC selection list, 3-89
DC power supplies, 2-45
Deactivate adaptation, 4-107
Dew-point temperature td, 5-185 I
Display options, 3-91
I component, 4-109
Drive data
Incremental encoder, 4-140
Dynamic model data, 4-139
Integrator feedback, 4-109
Mechanical design of drive, 4-137
Interfaces
Valve-to-drive connection, 4-137
Firmware, 1-15
Drive model data, Changing valve data, 3-59
Hardware, 1-15
Dust, hazardous, 5-187
Interfaces on mains supply module, 2-28
Dynamic drive model data, 4-139
Internet address, 8-238
Dynamic stiffness control (DSC), 4-114
M
Machine configuration, 3-49 P
Machine data groups, 3-91 Parameter set changeover, 4-98
Machine guideway Position adjustment, 3-67
Friction, 1-18 Position measuring system, 1-19, 4-140
Guide, 1-18 Actual position value, 4-144
Mains connection, 5-184 Linear scale graduations, 4-142
Manipulated variable inversion, 4-132 Phase error compensation, 4-141
Manipulated voltage limitation, 4-132 Possible dynamic response, 2-42, 4-95
Manipulated voltage output, 4-124 Power disable, 4-149, 4-150
Measurement function power enable, 4-149
Measurement of velocity controller, 3-78 Power supply
Position control measurement, 3-82 external, 2-45
Valve control loop measurement, 3-77 Internal, 2-45
Measuring system, 5-178 Preset unlisted valve, 3-55
Measuring system data Pressure sensing system, 4-145, 5-179
Absolute, 3-58 Offset adjustment, 4-145
Incremental, 3-58 Sensor adjustment, 4-145
Mechanical design of drive, 4-137
Modify drive machine data, 3-52
Monitoring
Limit frequency reached measuring R
circuit, 4-153 Reference model, 4-111
Measuring Circuit, 4-152 Referencing data for HLA
Power On alarms, 4-152 Piston zeroing, 3-67
Monitoring functions, 4-152 Position adjustment, piston position, 3-67
Mounting the HLA closed-loop control plug-in References, D-261
module, 2-29 Relative air humidity U, 5-185
Mounting/supply data Requirements of external 26.5 V supply, 2-45
Connection, 3-57
Drive data, 3-57
Supply unit, 3-57
S
Selection of servo solenoid valves
N Fail-safe position, 2-35
Flow characteristic
Natural frequency, 2-42 asymmetrical, 2-34
Natural frequency of hydraulic drive
Knee-shaped, 2-33
Possible dynamic response, 2-42
Linear, 2-33
Servo gain, 2-42
HR servo solenoid valves, 2-33
Notes
Pin assignments, 2-35
Hotline, 8-238
Preferred range of servo solenoid valves, 2-36
Technical Support, 8-238
Servo solenoid valve, 2-33
Valve size, 2-33
Valve types, 2-32
O Selection of shutoff valves
Objective, 1-15 General, 2-39
Offset adjustment Preferred range of shut-off valves, 2-41
Offset of pressure sensors, 3-64
Offset of valve manipulated voltage, 3-65
Reference value for pressure sensors, 3-65
W X111, 5-179
X112, 5-179
Weighting factor, 2-45 X121, 5-180
X122, 5-180
X141, 5-183
X X151, 5-183
X341, 5-183
X101, 5-178
X431, 5-181
X102, 5-178
X432, 5-181
Notes
Description of Functions
From
Order no.: 6SN1197-0AB60-0BP3
Name Edition: 10/03
SINUMERIK
SIROTEC
SINUMERIK SINUMERIK SIMODRIVE SINUMERIK SINUMERIK SINUMERIK SINUMERIK
840D/810D 840D/840Di/ Accessories 840D/810D/ 840D/840Di 840D/840Di/ 840D/840Di/
810D/ FM-NC 810D 810D 810D
Manufacturer/Service Documentation
SINUMERIK
SIMODRIVE SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK
611D 840D/840Di/ 840D/840Di/ 840D/810D 840D/810D 840D/810D
840D/810D 810D 810D
Manufacturer/Service Documentation
SINUMERIK
SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK SIMODRIVE
SIMODRIVE SINUMERIK SIMODRIVE SIMODRIVE SIMODRIVE SIMODRIVE SIROTEC
840D 840D/840Di 840D 840D
810D 611D 611D
611D