SINUMERIK 840D

SIMODRIVE 611 digital

Description of Functions 04.2000 Edition

HLA Module

Manufacturer/Service Documentation
 Overview of SINUMERIK 840D/840Di/810D/FM-NC Documentation (04.00)
General Documentation User Documentation

SINUMERIK
SIROTEC
SINUMERIK SINUMERIK SIMODRIVE SINUMERIK SINUMERIK SINUMERIK SINUMERIK
840D/810D/ 840D/840Di/ Accessories 840D/810D/ 840D/810D 840D/840Di/ 840D/810D/
FM-NC 810D/ FM-NC 810D/ FM-NC
FM-NC/611 FM-NC

Brochure Catalog Catalog AutoTurn Operator’s Guide Diagnostics Operator’s Guide

Ordering Info Accessories NC-Z -- Short Guide -- Unit Guide *) -- Short Guide
NC 60.1 *) -- Programming (1) Operator Panel -- Operator’s
Technical Info. -- Setup (2) -- HPU Guide *)
NC 60.2 -- HT 6

User Documentation Manufacturer / Service Documentation

SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK SINUMERIK

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

Program. Guide Operator’s Guide System Overview Description of Description of Descr. of Functions Configuring
-- Short Guide -- ManualTurn Functions Functions -- Computer Link (HW) *)
-- Fundamentals *) -- Short Guide ManualTurn -- ManualTurn Synchronized -- Tool Data -- FM-NC
-- Advanced *) -- ShopMill -- ShopMill Actions Information -- 810D
-- Cycles -- Short Guide ShopMill Wood, Glass, System -- 840D
-- Measuring Cycles Ceramics

Manufacturer / Service Documentation

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

Operator Description of Description of Configuring Kit Screen Kit Description of Description of

Components Functions Functions MMC 100/101 MMC 100/101 Functions Functions
(HW) *) Drive Functions *) -- Basic Machine *) -- Configuring SW Update and Tool Manage- Operator Interface
-- Extended Functions Syntax Configuration ment OP 030
-- Special Functions -- Development Kit

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
FM-NC
611D

Description of Description of Installation & Lists *) Description of Description of EMC

Functions Functions Start-up Guide *) Functions Functions Guidelines
SINUMERIK Digitizing -- FM-NC Linear Motor - Hydraulics
Safety Integrated -- 810D Module
-- 840D/611D - Analog Module
-- MMC

Electronic Documentation Manufacturer / Service Documentation

SINUMERIK
SIMODRIVE
SINUMERIK SINUMERIK SINUMERIK
840D/810D/
FM-NC 840D/810D 840Di
611,
Motors

DOC ON CD *)
The SINUMERIK System
Descr. of Functions Descr. of Functions Manual
ISO Dialects for CAM Integration (HW + Installation
SINUMERIK DNC NT-2000 and Start-up)
*) These documents are a minimum requirement for the control
 General 1
Configuring 2
Start-Up 3
Firmware Drive
Functions 4
SINUMERIK 840D
SIMODRIVE 611 digital Hardware Drive
Functions 5

HLA module Hydraulics Diagnostics 6

Peripherals/Accessories 7
Description of Functions
Service 8

Hydraulics A
Valid for

Control Software version

Abbreviations B
SINUMERIK 840D 5
SINUMERIK 840DE (export version) 5 Definition of Terms C
References D
EC Declaration of
Conformity E
Index F

04.00 Edition
 SINUMERIK Documentation
3ls

Printing history

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

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

Status code in the ”Remarks” column:

A . . . . . New documentation.
B . . . . . Unrevised reprint with new Order No.
C . . . . . Revised edition with new status.
If factual changes have been made on the page in relation to the same software
version, this indicated by a new edition coding in the header on that page.

Edition Order No. Remarks

02.99 6SN1197–0AB60–0BP0 A
08.99 6SN1197–0AB60–0BP1 C
04.00 6SN1197–0AB60–0BP2 C

This manual is included in the documentation on CD-ROM (DOCONCD)

Edition Order No. Remarks
04.00 6FC5 298–5CA00–0BG2

Trademarks
SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr und SIMODRIVEr sind Marken von
Siemens. 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.

Other functions not described in this documentation might be

Further information is available on the Internet under: executable in the control. However, no claim can be made regarding
http://www.ad.siemens.de/sinumerik the availability of these functions when the equipment is first supplied
or for service cases.

This publication was produced with Interleaf V 7.0. We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
The reproduction, transmission or use of this document or its exist and therefore we cannot guarantee that they are completely
contents is not permitted without express written authority. Offenders identical. The information contained in this document is, however,
will be liable for damages. All rights, including created by patent grant reviewed regularly and any necessary changes will be included in the
or registration of a utility model or design, are reserved. next edition. We welcome suggestions for improvement.

 Siemens AG 2000. All rights reserved Subject to changes without prior notice.

Order No. 6SN1197–0AB60–0BP1 Siemens Aktiengesellschaft

Printed in the Federal Republic of Germany
02.99

Preface
User information

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 HLD module is part of the
SIMODRIVE/SINUMERIK range of documentation.
For further information about the publications listed in the documentation over-
view and other available SIMODRIVE/SINUMERIK publications, please 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 “HLD modules”.

Aim This Description of Functions provides the information required to configure and
start up the hydraulic drive module.

S Chapter 2 describes the procedures to be followed to configure electrical

and hydraulic components.

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

S Functionalities provided by the firmware and the HLD module hardware are
explained in Chapters 4 and 5.

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

S Chapter 7 describes the accessories required, such as measuring system

and cables.

S Appendix A contains general information and an explanation of hydraulic

system functionalities.

Note
Hydraulics
Information about special hydraulics functions mentioned in this document refer
to functions supplied by Bosch.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition v
 02.99

Should further information be desired or should particular problems arise which

are not covered sufficiently for the purchaser’s purposes, the matter should be
referred to the local Siemens Sales Office.

How to use this The following guide information is provided to help you reference information in
manual this Description of Functions:

S General table of contents

S Header (as orientation aid):
– The top line of the header is the main section number
– The second line of the header is the subsection number

S Appendix with
– abbreviations, terms and references
– glossary (index)
If you require further explanation of a particular term, function or opera-
tion, you will find references to pages containing further relevant informa-
tion in the glossary.

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

S Trained and authorized to energize, de-energize, ground and tag circuits

and equipment in accordance with established safety procedures.

S Trained in the proper care and use of protective equipment in accordance

with established safety procedures.

S Trained in rendering first aid.

Software The SW versions specified in this documentation refer to the SINUMERIK 840D
versions control system and the HLD module.
The Description of Functions applies only to the software versions specified.
When a new software version is released, the Description of Functions for that
version must be ordered.

Important
! This documentation applies to:

S SINUMERIK 840D control and SIMODRIVE 611 digital drive system,

software version 5

 Siemens AG 2000. All rights reserved

vi SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99

Explanation of
symbols

Important
! This symbol always appears in the documentation when important information
is being conveyed.

Order data option

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

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

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

Caution
! This symbol appears whenever minor physical injury or material damage may
occur if the appropriate precautions are not taken.

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

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition vii
 02.99

Technical information

Warning
! Operational electrical equipment has parts and components which are at haz-
ardous voltage levels.
Incorrect handling of these units, i.e. not observing the warning information, can
therefore result in severe bodily injury or property damage.
Only appropriately qualified personnel may commission/start-up this equip-
ment.
This personnel must be thoroughly familiar with all the warning information and
service instructions given in this Description.
Perfect and safe operation of this equipment assumes professional transport,
storage, mounting and installation as well as careful operator control and ser-
vicing.
Hazardous axis motion can occur when working with the equipment.

Note
When handling cables, please observe the following:

S They must not be damaged

S They must not be stressed
S They must not come into contact with rotating components.

Warning
! Before the plant voltage test on the electrical components of machinery is car-
ried out, all terminals on the SIMODRIVE device must be disconnected
(EN 60204-1 (VDE0113-1), para. 20.4).
This is necessary to avoid subjecting pre-tested isolation on the SIMODRIVE
equipment to any unnecessary additional stresses.

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

 Siemens AG 2000. All rights reserved

viii SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99

Warning
! The information and instructions in all the documentation supplied and any
other instructions must always be observed to eliminate hazardous situations
and damage.

S The information given in catalogs and quotations applies additionally to

special versions of machines and equipment.

S Furthermore, all relevant national, local and plant-specific regulations and

specifications must also be taken into account.

S All work must be undertaken with the system in a no-voltage condition

(powered down!)

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition ix
 02.99

ESDS instructions Components which can be destroyed by Electro Static Discharge

Components which can be destroyed by electrostatic discharge are individual

components, integrated circuits or boards which, when handled, tested or
transported, could be destroyed by electrostatic fields or electrostatic dis-
charge. These components are designated as ESDS (ElectroStatic Discharge
Sensitive Devices).
Handling ESDS boards:
S When handling components which can be destroyed by electrostatic di-
scharge, it must be ensured that personnel, the workstation and packaging
are well grounded,.
S As a general rule, electronic boards should only be touched when absolu-
tely necessary.
S You may only touch ESDS components if
– you are continuously grounded via an ESDS bracelet,
– you are wearing ESDS shoes or ESDS shoe grounding strips in con-
junction with an ESDS floor surface.
S Boards may only be placed on conductive surfaces (desk with ESDS sur-
face, conductive ESDS foam rubber, ESDS packing bag, ESDS transport
containers).
S Boards may not be brought close to data terminals, monitors or television
sets (a minimum of 10 cm should be kept between the board and the
screen).
S Boards may not be brought into contact with materials which can be char-
ged and are highly insulating,
e.g. plastic foils, insulating desktops, articles of clothing manufactured from
man-made fibers.
S Measurements may be taken on the boards only if
– the measuring equipment is grounded (e.g. via the protective conductor)
or
– in the case of floating measuring instruments, the probe is briefly dis-
charged before a measurement is taken (e.g. through contact with bare
control housing).
S Closed-loop control modules, option modules and memory submodules
may only be held by the front plate or on the board edges.

 Siemens AG 2000. All rights reserved

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

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.1 Examples of applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.2 Comparison of electrical and hydraulic drive systems . . . . . . . . . . 1-16
1.3 Construction of an electro-hydraulically controlled drive axis . . . . 1-18
1.3.1 Machine guideway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.3.2 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.3.3 Servo solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.3.4 Valve amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.3.5 Shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.3.6 Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital . . . . . . . . . . . . . . . . . . . 1-20
1.3.8 Hydraulic power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2 Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.1 Configuring steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.1.1 Procedure for configuring electrical components . . . . . . . . . . . . . . . 2-21
2.1.2 Procedure for configuring hydraulic components . . . . . . . . . . . . . . . 2-22
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital . . . . . . . 2-24
2.2.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.2.2 Required FW packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.2.3 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.3 Configuring the hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.3.1 Cylinder selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.3.2 Selection of servo solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.3.3 Selection of shutoff valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2.3.4 Natural frequency of hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.3.5 Hydraulic power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.4.1 Internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.4.2 External power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.4.3 Earthing system/electromagnetic compatibility (EMC) . . . . . . . . . . 2-49
3 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.1 Overview of start-up process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.2 Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.3 Drive machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.4 Valve selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.5 Cylinder selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.6 Mounting/supply data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.7 Measuring system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.8 Changing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

 Siemens AG 2000. All rights reserved

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3.9 Fine adjustment and optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3.9.1 Control direction, travel direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3.9.2 Offset adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.9.3 Velocity compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3.9.4 Referencing data for HLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.9.5 Controller optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.9.6 Controller adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.9.7 Hydraulic/electrical interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.10 File functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.11 Start-up functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3.11.1 Measurement function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
3.11.2 Function generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3.11.3 Circularity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.11.4 Servo trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.11.5 DAC parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.12 User views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.13 Display options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.14 Configuring an OEM valve list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
4 Firmware Drive Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4.1 Block diagram of closed-loop control . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4.2 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
4.2.1 Overview of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
4.2.2 System environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
4.3 Closed-loop velocity control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
4.3.1 Velocity adaptation/feedforward control . . . . . . . . . . . . . . . . . . . . . . . 4-100
4.3.2 Velocity controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
4.3.3 Dynamic Stiffness Control (DSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
4.4 Closed-loop force control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
4.4.1 Force limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118
4.4.2 Static friction injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
4.4.3 Force controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120
4.5 Output of manipulated variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125
4.5.1 Characteristics compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125
4.5.2 Control output filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130
4.5.3 Manipulated voltage limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
4.6 Supply unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-133
4.7 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
4.8 Cylinder drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
4.9 Drive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
4.10 Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-140
4.11 Pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143
4.12 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
4.13 Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-150
4.13.1 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-150

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xii SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
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4.13.2 Variable signalling functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152

4.14 Service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-157
4.14.1 Min/max display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-157
4.14.2 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158
4.14.3 Diagnostic machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-159
4.15 Table of parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-163
5 Hardware Drive Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-173
5.1 Overview of interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-174
5.1.1 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-176
5.1.2 Pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-177
5.1.3 Servo solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-178
5.1.4 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-179
5.1.5 Test sockets (diagnosis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-180
5.1.6 Bus interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-181
5.2 System environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-182
5.3 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-183
5.3.1 Climatic and mechanical environmental conditions in operation . . 5-183
5.3.2 Shipment and storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
5.3.3 Resistance to pollutants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-185
6 Hydraulics Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-187
7 Peripherals/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-215
7.1 Measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-215
7.1.1 Encoders, linear scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-215
7.1.2 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-218
7.2 BERO (X432) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-221
7.3 Pressure sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-222
7.3.1 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-222
7.3.2 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-226
7.4 Connection diagrams for servo solenoid valves . . . . . . . . . . . . . . . . 7-227
8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-231
8.1 Areas of responsibility of Siemens and Bosch . . . . . . . . . . . . . . . . . 8-231
8.2 Hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-232
A Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-233
A.1 Servo solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-233
A.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-233
A.1.2 Servo solenoid valves of sizes 6 and 10 . . . . . . . . . . . . . . . . . . . . . . A-242
A.1.3 Pilot-actuated sizes 10 and 16 servo solenoid valves . . . . . . . . . . . A-244
A.1.4 HRV valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-247
A.2 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-249

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 xiii
Edition
 04.00
02.99

B Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-251
C Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-255
D References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-257
D.1 Electrical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-257
D.2 Hydraulic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-266
E EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-267
F Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-271

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xiv SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
General 1
1.1 Examples of applications

Examples of The NCU 573.2 of the SINUMERIK 840D is capable of handling axis
applications configurations of a maximum of 31 axes in 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 controlling 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 SIMO-
DRIVE 611 converter system mounted in a 50 mm carrier module (universal
empty housing).
The gating and closed-loop control electronics for operating 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
electrical and hydraulic drives as “equal partners” and integrating them into a
standard NC.

Objective To place equal emphasis on the functional importance of both hydraulic and
electrical 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

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 1-15
1 General 02.99
1.2 Comparison of electrical and hydraulic drive systems

1.2 Comparison of electrical and hydraulic drive systems

Table 1-1 Comparison of electrical and hydraulic drive systems

Criterion Electrical direct drive Electrical drive with Hydraulic drive

leadscrew
Power density / S Electrical part on S Servomotor and lead- S Cylinder and servo sole-
mounting machine table screw large and noid valve are light-weight
space require-
ments
S is light and requires heavy. and compact.
little space. S Problematic with lim- S Transfer of E motor to
ited mounting space. hydraulic power unit.
Mass inertia of Electrical part on Servomotor and lead- Piston and piston rod have
moving parts machine table has low screw have high mass very low mass
mass. moment of inertia.
Operational Service life depends in S Shock-sensitive. S Protected against overload
reliability, ser- principle only on linear
vice 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 requirement peaks by hy-
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 (
6MN)
forces approx. 40 to 80 kN/m2 forces. (Cylinder φ, pmax=315 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 Up to 500 m/min vmax=hs  ωmax/2π 120 m/min
velocity hs=thread lead with standard servo-cylinder
ωmax=max. motor speed
Maximum Unlimited
6m 1m
travel path
Collision Mechanically difficult Mechanically possible Mechanically possible
protection

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1-16 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 1 General
1.2 Comparison of electrical and hydraulic drive systems

Table 1-1 Comparison of electrical and hydraulic drive systems

Criterion Electrical direct drive Electrical drive with Hydraulic drive

leadscrew
Noise Noise produced by Noise produced by servo- S Flow through valve may
linear guides motor and leadscrew produce noise.
S Pump noise on
hydraulic power unit.
Acceleration Max. 45 g Max. 1 g Max. 2 g
characteristics
Drive cooling Mandatory Required only at high Required in some cases, in
speeds power unit only
Sensitivity to High Low Low
ferromagnetic
swarf

Table 1-2 Analogy of characteristic data

Electrical Hydraulic
Speed –
Speed Speed
Current flow
DC link voltage System pressure
Power Flowrate  Valve pressure difference
Transistor/power section Valve
motor Drive cylinder

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 1-17
1 General 02.99
1.3 Construction of an electro-hydraulically controlled drive axis

1.3 Construction of an electro-hydraulically controlled drive

axis

SINUMERIK 840D,
SIMODRIVE 611 digital
with HLA module Servo solenoid value with
valve amplifier (OBE)

Machine guideway

Shutoff valve

Position measuring
Hydraulic power unit system

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

1.3.1 Machine guideway

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

Friction A certain degree of friction can be very useful for the purpose of damping os-
cillations.
However, excessive friction, especially pronounced transitions from static to
sliding friction, have a negative effect on the control result and impair the control
loop stability.

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1-18 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 1 General
1.3 Construction of an electro-hydraulically controlled drive axis

1.3.2 Cylinders

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.

Quality criteria The following are critical quality criteria:

S The surface quality of barrel and piston rod and
S The seals and guides (low-friction, servo quality...).

1.3.3 Servo solenoid valve

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.
definiert.

1.3.4 Valve amplifier

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 manipulated variable
(U=0...10 V).

1.3.5 Shutoff valve

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

1.3.6 Position measuring system

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

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 1-19
1 General 02.99
1.3 Construction of an electro-hydraulically controlled drive axis

Function The speed is acquired through continuous differentiation of distance over time.
Various systems are available depending on the level of accuracy required.
The highest accuracy requirements are fulfilled by digital systems (glass 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.

1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital

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

S the shutoff valve,

S the servo solenoid valve,
S the position measuring system and
S the central arithmetic logic unit
are all provided by the HLA module.
The HLA module is an integral component of the SINUMERIK 840D and
SIMODRIVE 611 digital systems.
A range of different NCU modules with graded scope of functions is provided to
allow the SINUMERIK 840D system to be tailored to the varying functional re-
quirements of machines. The control can therefore be optimally adapted to indi-
vidual machines and machining applications and is suitable for equipping stan-
dardized machine series.

1.3.8 Hydraulic power unit

This unit supplies hydraulic energy.

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

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1-20 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Configuring 2
2.1 Configuring steps

2.1.1 Procedure for configuring electrical components

The procedure for configuring an HLA module is divided into steps in such 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 611D and SINUMERIK 840D.
Further configuring instructions and detailed ordering information can be found
in Catalogs NC 60 and NC Z.

Phase 1
Selection of hydrau- Section 2.3
lic components and Bosch publication
Dimensioning of incom- Section 2.2
ing mains supply and publication 6SN1197-0AA00
Dimensioning of Section 2.2
power modules and publication 6SN1197-0AA00
Dimensioning of exter- Section 2.4
nal power supply
Dimensioning of Chapter 4
closed-loop control components
Dimensioning of position Section 7.1
sensor (measuring system)

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

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-21
2 Configuring 02.99
2.1 Configuring steps

Phase 2
Recommended circuits
Section 2.4
EMC measures
Block diagrams/
connection diagrams Section 2.2

Abbreviations, Appendix
terms and index

Fig. 2-2 2nd configuring phase

2.1.2 Procedure for configuring hydraulic components

Hydraulically controlled drives are normally configured by the technical sales

and marketing personnel of the hydraulics supplier (e.g. Bosch, see Chapter 8
for contact address) in close co-operation with the machine manufacturer.
This configuring phase is divided into the following steps:

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

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

S Selection of position measuring system, plus pressure sensors in some

cases, on the basis of measuring range, accuracy and linearity (see Section
7.1, 7.3).

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

S Calculation of natural frequency of drive for initial assessment of whether

expected control result can be achieved (see Section 2.3.4).

S Bosch sales personnel are assisted by the “Hydro 2” hydraulic configuration

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

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2-22 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.1 Configuring steps

Questionnaire Design of hydraulic NC axes

Hydraulic NC axes
Design of systems with linear motions

Company: Contact person:

Address: Department:

Telephone:

Machine:

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

Drive specification
Cylinder dimensions [mm] Accuracy requirements
Piston diameter: Positioning precision [mm]
1 rod diameter: from rapid traverse:
2nd rod diameter: from feedrate:
Stroke: Path accuracy:
Cylinder mounting position: Velocity
tolerance [mm/min]:
051–001/

Connections: Position measuring system incremental,

Valve – cylinder output signal ...
Pipe/Hose length [mm]: Make:
Pipe/Hose diameter [mm]: Type:
Moved mass [kg]: Other:
Machining forces [N] Resolution [mm]:
Piston advance:
Piston retraction:
Slide guide friction Numerical control
m: Make: SIEMENS
FR [N]: Type: 840D
Pump pressure [bar]:
Velocities [m/min]
Rapid traverse advance:
Rapid traverse retract:
Machining feed advance:
Machining feed retract:
Acceleration rates [m/s2]
Max. acceleration:
Max. delay:

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

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-23
2 Configuring 02.99
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2.1 System overview

Components A complete 840D control system with HLA module consists of various individual
components. These are listed in the table below.
Table 2-1 Components of 840D with HLA module (number, component,
description)

No. Component Description

A NCU box S Enclosure for NC CPU
B NC CPU S Central processing unit of 840D
S Execution of NC program,
S Contains modules with e.g. PLC, communications
functions
S NCU 573.2 includes a fan module
B1 Cable distributor S For insertion in NCU
C1) Operator panel S Display, keyboard, power supply and NC
operating components
D1) MMC module S Operator panel calculator (integrated in panel),
S MMC 103 with hard disk
E Mains infeed (NE) References: /PJ1/ SIMODRIVE 611
F1) Machine control panel S Machine operation
G1
1)
ISA adapter S Allows AT modules to be used in conjunction with
the MMC module MMC103 (mounted in operator
panel)
G2
1)
CNC full keyboard S Full keyboard for connection to MMC module

G3 Memory card (PCMCIA) S Contains the system program,

S can be slotted into the NCU 561.2, 571.2, 572.2,
573.2
G4 Diskette unit (accessory) S Built-in unit for connection to MMC module
H1 Cables References: /Z/, Accessories Catalog NC Z
to
H9
H10 Cables See Section 7, Peripherals/Accessories
to
H12
I SIMODRIVE hydraulics S Closed-loop control of hydraulic drive
module (HLA module) S Actuation of servo solenoid valve
50 mm carrier module (uni- Holder for HLA closed-loop control plug-in module
versal empty housing) (see Fig. 2-6)
I1 Phoenix cable connection S Shutoff valve
S External 24 V supply
S BERO input
S “power enable”
J SIMATIC components References: /S7H/, Manual
K Terminator Terminator for drive bus (inserted in last module in
drive grouping)

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2-24 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

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

description)

No. Component Description

L1) Hand-held unit S Connect HHU to K bus via MPI
S Handwheel, EMERGENCY STOP button, keys-
witch, override, enable keys, display, free keys
M
1)
Distribution box S For linking the hand-held unit to the MPI bus
S Connection for EMERGENCY STOP circuit, ena-
ble keys, handwheel, 24 V DC
N Cable distributor S 24 V supply for connection to MPI connector
O Hydraulic drive References: AKY o13/2; BEY 014/4; BEY 013/31
P External 24 V supply S SITOP stabilized power supply modules

References: Catalog SITOP power

Order No. E80001-V0752-A253

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

References: /BH/, Operator Components Manual

Note
An HLA module must never be operated directly on a SIMODRIVE monitoring
module, i.e. it must 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
SIMODRIVE 611 Planning Guide (/PJ1/).
In a multi-tier configuration, all incoming supply units must be switched in simul-
taneously.

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-25
2 Configuring 02.99
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

Floppy
G4

ÄÄ
ÄÄ
MMC CPU D
J G1

S7-300
L
C
H1
H5

F
MCP

H4

G2
H6
M
E
H8
B
B1

N
I1 O
H10
G3
K
Device bus
A
I Position sensor
NE NCU HLA
module
H11
H12 Pressure sensor A
H2 Battery and fan plug-in
unit Pressure sensor B
H3
Digital I/O
H9 (high-speed NC I/O)

Servo solenoid
Measurement (2x) valve

Handwheel BERO inputs

(2x)
(1x of M) Shutoff valve
SITOP power Enable signal
(external PS)

P
Supply 26.5 V external Note:
Display of hydraulics for one axis

Fig. 2-3 System components

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2-26 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

Servo solenoid Servo solenoid

valve valve

A Pressure sensor A A
Pressure sensor A
B Pressure sensor B B
Pressure sensor B
Position sensor Position sensor

Shutoff valve Shutoff valve

Hydraulic drive, axis 1 Hydraulic drive, axis 2

Axis 1 HLA Axis 2

–X101

–X102

Position measur- Position measuring

ing system system
B B
A A
–X112
–X111

Pressure sensor Pressure sensor

–X121

–X122

Servo solenoid Servo solenoid

valve valve

X431 X432

–X35
–X34

M Electronics ground M Electronic ground1)

PV1 + Shutoff valve, axis 1 PV2 + Shutoff valve, axis 2
MV1 – Reserved, do not use!
MV2 – Reserved, do not use!
C1 C2
X1141

X1341

P24 + Supply 26.5 V external B1 BERO input, axis 1

M24 – 19 Internal 0 V enabling voltage
663 Power enable at term. 663 B2 BERO input, axis 2
9 Internal +24 V enabling voltage 9 Internal +24 V enabling voltage

Drive bus Drive bus/drive bus terminator

on last module
Device bus interface (X151)

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

Fig. 2-4 Connection configuration for HLA module

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-27
2 Configuring 02.99
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

74
Relay contact for NC contact
Ready signal 73.1
73.2 X111
NO contact
72
Relay contact for group signal I2t and mo- 5.3
tor overtemperature 5.2
5.1
Power disable 63
Enable voltage 9 X121
Enable voltage 9
Drive enable signal 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)
Enable voltage 9
Setup mode 112
Energize contactor, start 48
Line contactor signalling con- 111 X161
213
tact 113
1)
NS1 X171
Enable signal for internal line con-
tactor NS2
AS1 X172
Starting disable signalling contact
(NC) AS2

LED
displays
X351
DC link power supply for bridging M500
power failures P500
Electronics power supply from 2U1
external source 1U1 X181
Electronics power supply from Device
2V1
external source 1) bus
1V1
Electronics power supply from 2W1
external source
1W1

P600

DC link
connection
LED displays M600
Electronics power
5V voltage
supply faulty red
red level faulty
Device is not ready,
enable signal (term. green yellow Device ready
63, 64 or 48) missing (DC link
precharged)
red red
Mains fault
DC link
overvoltage

1) Jumpers inserted in delivery state Mains

connection
U1 V1 W1 X131 PE

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

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2-28 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 04.00
02.99 2 Configuring
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

Mounting the HLA

closed-loop control
plug-in module

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

HLA closed-loop control

plug-in module
(6SN1115-0BA11-0AA0)

Slotted screw
M3 / 0.8 Nm

P600

M4 / 1.8 Nm
M600
Order No.

Rating plate/Order No.

PE
Slotted screw
M3 / 0.8 Nm M5 / 3.0 Nm

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

2.2.2 Required FW packages

S SINUMERIK 840D NCK SW  5.1
incl. SIMODRIVE 611 digital HLA Module  1.0
S SINUMERIK 840D MMC SW  5.1
2.2.3 Hardware requirements
S NCU 561.2, 571.2, 572.2, 573.2

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-29
2 Configuring 02.99
2.3 Configuring the hydraulic drive

2.3 Configuring the hydraulic drive

General Hydraulic drives are generally configured by technical sales and marketing per-
sonnel from hydraulics supplier Bosch. Bosch personnel are supported by the
“HYDRO 2” calculation program (for internal use only). The data supplied by the
customer on the questionnaire described in Section 2.1.2 serve as initial dimen-
sioning information.
Please refer to Appendix A for a description of hydraulic components.
The hydraulic drive is configured in the sequence of steps described below.

2.3.1 Cylinder selection

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

Table 2-2 Typical cylinder data

Designation Diameter
Piston ∅ 25 32 40 50 63 80 100 125
Rod ∅ Standard 12 14 18 22 28 36 45 56
Rod ∅ Optional 18 22 28 36 45 56 70 90

Stroke length The stroke is identical to the working stroke of the drive, with some additional
safety reserves.

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2-30 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

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

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

Fig. 2-8 Cylinder mounting position

Seal, Friction Low friction can be maintained by using suitable seals. Transitions from static to
sliding friction have a particularly adverse affect on the control result.
The slide guide friction must be added to the cylinder friction. A friction com-
pensation function can be activated in the HLA module (MD 5460:FRIC-
TION_COMP_RADIENT) in order to overcome initial friction.

Cylinder pipes The distance between the cylinder and servo solenoid valve must be kept as
short as possible for the sake of the frequency (compressibility of 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. The HLA module does not sup-
port cylinder-integrated position measuring systems (magnetostrictive or poten-
tiometer).

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-31
2 Configuring 02.99
2.3 Configuring the hydraulic drive

2.3.2 Selection of servo solenoid valves

References: Bosch AKY 013/2
Valve types The HLA module supports Bosch servo solenoid valves with integrated (OBE)
(overview) electronics, for which technical data are stored in the software of the module, as
well as valves supplied by other manufacturers. The drive is parameterized au-
tomatically when the order number is entered. The following table shows an
overview of the servo solenoid valves supplied by Bosch.
For a complete list, please see Tables 2-5 to 2-11.
Table 2-3 Valve types

Name Nomi- Volumetric flow Character- Limit fre-

nal Qnom (l/min at∆p istic quency 1)
size (bar) (Hz)
Size 6 up to 40 / 35 bar linear and 110
Directly actuated servo
with knee
solenoid valve

Size up to 100 / 35 bar linear and 85

10 with knee

Size up to 70 / 5 bar with knee 40

Pilot-actuated servo 10
solenoid valve

Size up to 150 / 5 bar with knee 40

16

Size 6 up to 40 / 35 bar linear and 210

High Response Valve with knee
(HRV1)

High Response Valve Size up to 70 / 35 bar with knee 80

(HRV2) 10

Size up to 150 / 5 bar with knee 80

16

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

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2-32 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

The selection of a valve for a particular application is made according to the

criteria described below.

Valve size The valve size is generally determined by the maximum flow QX. The flow is
calculated from piston area A which is already known (see Section 2.3.1) and
rapid traverse v according to the following law of flow:
QX=v  A
The nominal volumetric flow Qnom when the valve is completely open (i.e. when
actuating signal is U=+ or –10 V) only serves as a rough guide, as this value
refers to a pressure loss per control edge of ∆p=35 bar or ∆p=5 bar, as stated in
table 2-3. The actual flow under practical pressure conditions is calculated ac-
cording to the following formula:

∆pX
QX=Qnom 
∆pnom

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

Table 2-4 Extract from “HYDRO 2” program

1. Given or previously calculated data (input)

Piston diameter D (mm) 63
Rod diameter d (mm) 28
Counteracting force F (kN) 30
Pump pressure pp (bar) 120
2. Alternative valve size selections (input) Alt 1 Alt 2 Alt 3
Rated flow Qno (l/min) 24 50 100
m
Rated pressure drop ∆p (bar) 35 35 35
3. Alternative results on travel-out (output)
Speed v (m/min) 4,6 9,7 19,3
Pressure in A pA (bar) 104.3 104,3 104,3
Pressure in B pB (bar) 10,1 10,1 10,1
Pressure drop in inlet ∆pPA (bar) 15,7 15,7 15,7
Pressure drop in outlet ∆pBT (bar) 10,1 10,1 10,1

v
F

PA PB

∆PPA ∆PBT
PP PT=0

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

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-33
2 Configuring 02.99
2.3 Configuring the hydraulic drive

Characteristic Values with either a linear or knee-shaped characteristic can be selected.

The latter are suitable for obtaining a higher resolution in the low signal range
(machining) and sufficient flow in the high signal range (rapid traverse).
The definition of the knee-point position as 40% or 60% means that only 10 %
of the opening cross-section (flow) is released at 40% or 60% of the control sig-
nal (i.e. at U=4 V or 6 V).
The knee-shaped characteristic of the valve must be linearized in the HLA mod-
ule to adapt it to the closed-loop control of the entire drive (cylinder).

+Q +Q
Valve
characteristic
Rapid traverse
Linearized
characteristic
10 10
–UE +UE –UE +UE
40 40
Machining Compensation

velocity

–Q –Q

Fig. 2-10 Characteristic of servo solenoid valve

Note
Recommended selection:
Servo solenoid valves are generally recommended for applications where there
is a clear separation between machining operation and rapid traverse.

Servo solenoid or HRV valves (High Response Valve) are characterized by a better dynamic re-
HRV valves sponse, i.e. by a higher limit frequency as compared to servo solenoid valves.
They react with greater sensitivity to setpoint changes especially in the small-
signal range. The use of HRVs is recommended in the following cases:
1. When extremely high contour precision is required in high-speed continu-
ous-path control machining operations.
2. When very high response sensitivity is required to achieve the best possible
positioning accuracy.
It must be noted that HRVs do not generally have a “fail-safe” position. The con-
nector has 12 pins instead of the 7-pin connector on servo solenoid valves.

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2-34 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

“Fail-safe” Directly actuated, servo solenoid valves have a “fail-safe” position which they
position assume when the power supply is disconnected so as to ensure that the cylin-
der remains stationary. However, when the power supply is connected and dis-
connected or the valve is forced to slide through the crossed position, brief
reactions at the cylinder end cannot be precluded.
An absolutely safe stop with loaded cylinder (e.g. vertical mounting position)
can only be guaranteed with a “fail-safe” valve in conjunction with additional
shutoff valves.
Pilot-actuated servo solenoid valves and HRVs have no defined “fail-safe” posi-
tion. They assume a zero-overlapped mid-position (not a safe stop position)
when the supply is disconnected.

Fail-safe disabled (a) Fail-safe enabled

A B A B

P T P T

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

Asymmetrical Pilot-actuated servo solenoid valves with asymmetrical throttle cross-sections

characteristics are used to achieve a sufficiently powerful throttling effect when lowering vertical
differential cylinders with suspended load on the piston rod.

QA
+Q

PA
v

PB
–UE +UE
A B QB

P T
–Q

Fig. 2-12 Asymmetrical characteristics

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-35
2 Configuring 02.99
2.3 Configuring the hydraulic drive

Connector pin A distinction must be made between servo solenoid valves and HRVs.
assignments
S Servo solenoid valves (directly and pilot-actuated): 7-pin round connector

2.5 AF
A +24 V=
B 0V Supply
C 0V Reference point for actual
D valve spool value
100k E Setpoint 0...10 V
100k F Sign.
10k Actual value spool value
Protective earth

Screening

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

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

2.5 AF
+24 V=
0V Output stage supply

+UB 1 24 V
2 Enable signal
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 earth

Screening

Fig. 2-14 Connector pin assignment on on HRVs

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

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2-36 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

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

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 35 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 600 4 linear 7-pin A B AKY 013/2
0 811 404 601 12 linear
0 811 404 602 24 linear
P T
0 811 404 603 40 linear
0 811 404 610 4 linear A B
0 811 404 611 12 linear
0 811 404 612 24 linear
P T
0 811 404 613 40 linear
0 811 404 642 15 60 A B
0 811 404 643 25 60

0 811 404 644 40 40 P T

0 811 404 645 15 60 A B

0 811 404 646 25 60

0 811 404 647 40 40 P T

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

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

P T

Table 2-6 Size 10 servo solenoid valves, directly actuated

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 35 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 800 50 linear 7-pin A B AKY 013/2

0 811 404 801 100 linear

P T
0 811 404 802 50 linear A B

0 811 404 803 100 linear

P T
0 811 404 822 50 40 A B

0 811 404 823 100 40

P T

1) Asymmetrical characteristic

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-37
2 Configuring 02.99
2.3 Configuring the hydraulic drive

Table 2-6 Size 10 servo solenoid valves, directly actuated

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 35 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 824 50 40 A B AKY 013/2

0 811 404 825 100 40

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

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

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

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

P T

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

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 5 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 686 40 40 7-pin A B AKY 013/2
s u
0 811 404 687 70 40
s u
0 811 404 688 A:40; B:201) 40 X P T Y
0 811 404 689 A:70; B:401) 40

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

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 5 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 263 90 40 7-pin A B AKY 013/2
s u
0 811 404 264 150 40
s u
0 811 404 265 A:90; B:501) 40 X P T Y
0 811 404 266 A:150; B:901) 40

1) Asymmetrical characteristic

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2-38 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

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

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 35 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 720 40 linear 12-pin A B BEY 013/31
0 811 404 721 24 linear HRV – Size
S 6

0 811 404 722 12 linear

P T
0 811 404 723 8 linear
0 811 404 725 15 60
0 811 404 726 25 60
0 811 404 727 40 40
0 811 404 728 A:40; B:201) 40

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

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 5 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 693 40 40 12-pin A B BEY 013/31
0 811 404 694 70 40
0 811 404 695 A:40; B:201) 40
X P T Y
0 811 404 696 A:70; B:401) 40

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

Bosch Qnom (l/min) Characteris- No. of Graphic symbol Bosch

order number at 5 bar tic kneepoint connec- catalog
(100%) (%) tor pins
0 811 404 296 90 40 12-pin A B BEY 013/31
0 811 404 297 150 40
0 811 404 298 A:90; B:501) 40
X P T Y
0 811 404 299 A:150; B:901) 40

1) Asymmetrical characteristic

2.3.3 Selection of shutoff valves

References: Bosch BEY 010/4

General Additional shutoff valves, mounted as an intermediate plate below the servo
solenoid valve, ensure that the drive is switched on and off safely and prevent
backlash on transition from the “fail-safe” position to mid-position and vice
versa.
With external loads (vertical mounting), shutoff valves can prevent any inadver-
tent cylinder movement (downwards) when the control loop is not active.

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-39
2 Configuring 02.99
2.3 Configuring the hydraulic drive

The shutoff valves are automatically enabled and disabled in the correct switch-
ing sequence by the HLA module.
Start precondition: The hydraulic pressure must be available 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

S the tolerances of the capacitors,

S the voltage level of the external supply and
S the charging time of the integrated capacitors (instant of voltage failure).
The available reaction time is mainly defined by

S the power required for the current machining step,

S the response time of the shutoff valves and
S the trip threshold of the servo solenoid valves.

Example

A B
b
Servo solenoid
S U valve
P T

a Shutoff valve

P T B A

Fig. 2-15 Example of a shutoff valve application

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2-40 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

A B
Servo solenoid
b
S U
valve
P T

Shutoff valve
(additional
block)

P T B A

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

Preferred range of The following table lists all shutoff valves supplied by BOSCH that can be used
shutoff valves in conjunction with HLA modules.

Table 2-12 Shutoff valves

Bosch Nominal Graphic symbol Bosch

order number size catalog
0 811 024 120 Size 6 P T’ A’ B’ BEY 010/4
’

a
0 811 020 040 Size 10

P T A B
0 811 024 125 Size 6 P T’ A’ B’
’

P T A B
0 811 024 123 Size 6 P T’ A’ B’ BEY 010/4
’
b

P T A B
0 811 004 102 Size 6 A B P’ T’
’ ’
a

A B P T

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 2-41
2 Configuring 02.99
2.3 Configuring the hydraulic drive

Table 2-12 Shutoff valves

Bosch Nominal Graphic symbol Bosch

order number size catalog
0 811 004 103 Size 6 A T B’ P’
’ ’
b

A T B P
0 811 004 104 Size 6 B T A’ P’
’ ’
a

B T A P
0 811 024 122 Size 6 A B T’ P’
’ ’
a b

A B T P
0 811 024 121 Size 6 P A B’ T’
’ ’

P A B T

2.3.4 Natural frequency of hydraulic drive

Servo gain The implementable servo gain is essentially determined by the natural fre-
quency of the cylinder and its load ω0 and the limit frequency of the servo
solenoid valve ωv.
The cylinder and its load constitute a spring/mass system whose natural fre-
quency is calculated according to the following formula:
AR
A m
4  E  A ( 1 + α)
ωo 
mh 2
h

The letters have the

following meaning: E=Modulus of elasticity 1,1  109 (N/m2)
A=Piston area (m2)
AR=Ring surface(m2)
h=Stroke (m)
α=Surface ratio AR/A
m=Mass (kg)
Oil volumes in the cylinder pipes must also be taken into account.
The minimum natural frequency occurs only at a particular mid-position and
increases as the end positions are approached.
The calculation is made by means of the “HYDRO 2” program.

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2-42 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 2 Configuring
2.3 Configuring the hydraulic drive

Table 2-13 Extract from “HYDRO2” program

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

Piston diameter D (mm) 50 63 80
Rod diameter d (mm) 22 28 36
Stroke h (mm) 500 500 500
Mass on piston rod m (kg) 150 200 400
Servo solenoid valve, size Size Size Size
6 10 10
Limit frequency of servo solenoid valve fv (Hz) 85 45 45
Pipe length (cylinder/valve) (mm) 200 200 200
Internal pipe diameter (mm) 8 12 14
3. Calculated alternative results (outputs)
Natural frequency of cylinder f0 (Hz) 56,6 54,6 55,0
Natural frequency of hydraulic drive (incl. servo ft (Hz) 34 24,7 24,8
solenoid valve)
Stroke at which min. natural frequency occurs hx (mm) 265 266 266

h
d
hx

m f0
D
(oscillating mass)

The natural frequency of the hydraulic drive is automatically calculated by the

HLA module and applied in the controller once the corresponding data have
been parameterized. See also the following machine data in 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

Feasible The feasible dynamics of the servo solenoid valves (e.g. Bosch servo solenoid
dynamics valves used) is dependent on the valve modulation and is stated in the Bosch
catalog in Hz for the –90° corner frequency fo .
In the case of pilot-actuated valves, the valve dynamic response is not only de-
termined by the valve type, but also by the pilot pressure ppilot :
f0 ~ ppilot

The Bosch catalog data are referred to a pilot pressure of 100 bar.
Servo-valves can reach corner frequencies of up to 1000 Hz, but are very sen-
sitive to contamination.

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2 Configuring 02.99
2.3 Configuring the hydraulic drive

2.3.5 Hydraulic power unit

The hydraulic power is supplied by a hydraulic power unit installed separately or

integrated in the machine. The power unit is configured individually to meet the
requirements of all hydraulic loads. The following factors are of particular impor-
tance:

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

Flow Q The maximum flow rate 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 E motor to the pump drive is calculated from the
product of pressure p and flow Q.
P=pQ

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.

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.
In order to guarantee general operational reliability, but more importantly, to pro-
tect the control edges against premature erosion and 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 means of full flow filters of class β10=75 which must be ar-
ranged in the pressure pipe directly before the servo solenoid valve.
The most critical phase is start-up, since contamination which has accumulated
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.

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02.99 2 Configuring
2.3 Configuring the hydraulic drive



°C
P
Q

M

Variable displacement pump with pressure regulator

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

Oil reservoir

Fig. 2-17 Overview of typical hydraulic power unit

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2 Configuring 04.00
02.99
2.4 Wiring

2.4 Wiring

2.4.1 Internal power supply

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 840D and
power loss SIMODRIVE modules (power supply or incoming supply module, possibly feed
calculation for modules and/or main spindle modules). The power supply is fed in via the
NCU 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 facilitate the calculation, each module has a weighting factor.
This can be found in Chapter 9 of the following reference material:
References: /NC60.1/, Catalog SINUMERIK & SIMODRIVE
The sum of electronic and control points must not be larger than stated in the
data sheet of the power supply module.

2.4.2 External power supply

Requirements of The purpose of the external power supply is to switch and supply the
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).

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02.99 2 Configuring
2.4 Wiring

Warning
! S The DC supply must be reliably separated.
See also
References: /PHD/, NCU 561.2-573.2 Manual

S The DC supply must be connected to the electronics ground of the control

at one point (e.g. X131 on I/RF module. As a general rule, this connection
is already provided as standard in the S7-300 peripherals. See also
References: /EMV/, SINUMERIK, SIROTEC, SIMODRIVE,
EMC Installation Guideline

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 is referred to the input terminals of the closed-
loop control, the voltage drops on the supply leads are not negligible.
The external 26.5 V supply is monitored for violation of a lower limit in 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 dam-
age the module or external switch.

S If the external 26.5 V supply has to be switched, then an external “precharg-

ing circuit” (e.g. relay with timer and resistor) must be used.
S The 26.5 V outputs are short-circuit-proof or protected by fuses.
The outputs for the shutoff valves are designed as electronic switches with
integrated zener diodes for disconnecting inductive loads. The zener diodes
are located between the 24 V input and the output, with a typical zener volt-
age of 58 V.
On supply disconnection, the energy produced by the coil inductance and
the valve spool spring, plus the energy supplied from the 24 V source in the
zener diode and ohmic resistance in the solenoid coil is converted to heat.
This energy must not exceed 1.7 J during one power OFF process or else
the zener diode will be destroyed; no electronic protection against this type
of overload is available.
S Other requirements of the external 26.5 V supply:
– Voltage range (mean value) 25.97 V to 27.03 V DC
– Ripple 240 mVpp
– No voltage dips, otherwise disconnection

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2 Configuring 04.00
02.99
2.4 Wiring

Recommended The SITOP power product range supplied by SIEMENS is recommended for
power supply use as the external 26.5 V power supply.
References: Catalog, SITOP power from 2 to 40 A
Order No. E800001-V0752-A253

S SITOP power for mains connection

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

Table 2-14 SITOP power for mains connection

Input Output Order No.

Voltage Voltage range Voltage Current
Ve rated Va Ia rated
400 V 3 AC/ 360...550 V 24 V DC 10 A 6EP1 434 – 1SH01
480 V (24...28.8
(24 28 8 V)
tol. 1% 20 A 6EP1 436 – 1SH01

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

40 A 6EP1 437 – 1SL01

NE module HLA module

X431
P24EXTIN
5
M24EXTIN
6

X131

L1 SITOP M
L2
Mains L3 L+ (26.5 V)
AC/DC
PE

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

S SITOP power for DC link connection

(available soon)

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02.99 2 Configuring
2.4 Wiring

2.4.3 Earthing system/electromagnetic compatibility (EMC)

The 840D system with HLA module consists of a number of individual
components. The individual components are listed below:
S I/RF infeed/regenerative feedback module
S NCU box
S HLA module
S MCP machine control panel
S Qwerty keyboard
S Operator panel components (various monitors with different MMC CPUs)
S Terminal block (NCU and L2-DP)
S Distribution box and hand-held unit
The individual modules are bolted to a metal cubicle panel. It must be ensured
that a low-impedance contact between the NCU box and the cubicle panel can
be made in the vicinity of the mounting screws. Insulating varnishes must be
avoided where possible.
The electronic ground connections of the modules are interconnected via the
device and drive buses and taken to terminal X131 on the I/RF module at the
same time.
The internal electronics ground of the HLA module is directly connected to the
metal front (module) plate.

ÏÏÏ
ÏÏÏ
Gating HLA mod- Distribu-
electronics tion box

ÏÏÏ
NCU ule
Machine EPB/PE
Operator panel MMC
control panel

EPB/PE EPB/PE tGr

– Ground (chassis) –
tGr

S7-300 peripherals Terminal

block
EPB/PE Hydraulic drive EPB/PE
EPB EPB
Machine base

Earthing bar tGr: Shielded signal cable referred to ground

EPB: Equipotential bonding conductor Cross-sections (mm2)
PE: Protective earth 10
Mains connection S PE minimum
Central earth connection S
16 S
16  S
35 16
S  35 S/ 2

Fig. 2-19 Earthing system

Please note the following in relation to electromagnetic compatibility:
References: /EMV/, EMC Installation Guidelines
Standards according to Declaration of Conformity
(Appendix E)
J

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2 Configuring 02.99

Notes

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2-50 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Start-Up 3
3.1 Overview of start-up process

Cylinder Calculate drive Calculate

List selection model data controller data
Selection list: data Model Controller
Valve data Mechanical data data
data

Data input Data input Data input

Fig. 3-1 Overview of start-up process

Specially designed start-up menu displays are provided by the

SINUMERIK 840D control system.
Instructions for calling menu displays can be found in:
References: /IAD/, Installation and Start-Up Guide

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):

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

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3 Start-Up 02.99
3.1 Overview of start-up process

Machine data Hydraulic linear drives (HLA) are adapted to the machine by means of machine
data.
For this purpose, softkey “Drive MD” is included in the machine data menu
along with the other softkeys
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 Select a valve in list
2. Enter cylinder data
3. Mounting/supply data
4. Measuring system data
5. Calculate controller data, save boot file, NCK reset.
6. MD 5475: OUTPUT_VOLTAGE_LIMIT output voltage limitation to low 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” via these machine data or
automatically via MD 5650. Enter 1000 Hex in MD 5650. Data are reset to 0
after approximately 2 s and the sensors then adjusted. The sensors must be
unpressurized during adjustment.
9. Perform offset compensation with MD 5470.
Automatic offset compensation is possible via MD 5650 if 2000 Hex is en-
tered in MD 5650. Automatic offset compensation takes approximately 30 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. Friction compensation and force limitation
MD 5241=1000 Hex Force limitation active
MD 5241=2000 Hex Friction compensation active
MD 5241=3000 Hex Force limitation and friction compensation active

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02.99 3 Start-Up
3.2 Drive configuration

3.2 Drive configuration

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

Fig. 3-3 “Drive configuration” menu display

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

Table 3-1 Abbreviations of drive types

Drive Motors Contents of

MD 13040 DRIVE_TYPE
SRM (FDD) Synchronous rotating motor (1FT6...) 1
ARM (MSD) Asynchronous rotating motor (1PH...) 2
SLM Synchronous linear motor (1FN...) 3
HLD Hydraulic linear drive 5
ANA Analog drive 4
PER Peripherals 0

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

S MD 30110: CTRLOUT_MODULE_NR
S MD 30130: CTRLOUT_TYPE
S MD 30220: ENC_MODULE_NR
S MD 30240: ENC_TYPE
and initiated a NCK power ON/Reset (which opens the “Drive machine data”
menu display).

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3 Start-Up 02.99
3.3 Drive machine data

3.3 Drive machine data

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

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

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

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

Drive + Drive +

Drive – Drive –

Direct Direct
selection... selection

Valve/ Valve
Controller... selection... (see Fig. 3-6)

Boot file/ Change

NCK Res... valve data... (see Fig. 3-13)

Search... Calculate
controller (see Fig. 3-15)
data...
Continue Piston
position...
(see Fig. 3-21)
search

Display <<
options...
File File
functions functions

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

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3-54 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.4 Valve selection

3.4 Valve selection

3.4.1 General
You can select the servo solenoid valve from a list during initial start-up of the
SIMODRIVE 611 system. Once you have made your selection, the defaults of
the valve machine data 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 softkey starts the user-prompted start-up process for the HLA module.
softkey You can select a valve from a list stored in the module software, or a non-listed
valve, in the following menu display.

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

Enter “Unlisted valve” to call a new menu display (see Fig. 3-7) in which 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 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” softkey also activates a prompt box in
which you must confirm that you really want to abort start-up for this drive.
No data are ever changed when you select “Abort”. This also applies to the
following menu displays.

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3 Start-Up 02.99
3.4 Valve selection

If you select entry “Unlisted valve”, choose softkey “Continue” to go to menu

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

List selection of The following data are output in the MMC list display for a stored valve when
valve one is selected:

S Make e.g.: Bosch

S Order No. e.g.: 0811404829

S Name e.g.: size 10

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

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

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

S Code e.g.: 52

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

S MD 5106: VALVE_CODE (valve code no.)

S MD 5107: VALVE_NOMINAL_FLOW (rated flow rate of valve)
S MD 5108: VALVE_NOMINAL_PRESSURE (rated pressure drop of valve)
S MD 5109: VALVE_NOMINAL_VOLTAGE (rated valve voltage)
S MD 5110: VALVE_DUAL_GAIN_FLOW (knee-point flow rate of valve)
S MD 5111: VALVE_DUAL_GAIN_VOLTAGE (knee-point voltage of valve)
S MD 5112: VALVE_FLOW_FACTOR_A_B
(rated flow rate ratio between A and B ends of valve)

S MD 5113: VALVE_CONFIGURATION (valve configuration)

S MD 5114: VALVE_NATURAL_FREQUENCY (natural frequency of valve in
small-signal range)

S MD 5115: VALVE_DAMPING (valve damping)

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02.99 3 Start-Up
3.4 Valve selection

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

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

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

Fig. 3-8 Menu display “Preset unlisted valve 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.

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3 Start-Up 02.99
3.5 Cylinder selection

3.5 Cylinder selection

The following cylinder data must be entered manually:

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)

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

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

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3-58 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.6 Mounting/supply data

3.6 Mounting/supply data

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

By selecting softkey “Back”, you can return to the “Cylinder data for HLA” menu
display. Then press “Continue” to go to the “Measuring system data for HLA”
menu display.
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-actu-
ated valves only)

Connection
S MD 5140: VALVE_CYLINDER_CONNECTION
(valve-cylinder connection configuration)

S MD 5141: PIPE_LENGTH_A (pipe length at A end)

S MD 5142: PIPE_LENGTH_B (pipe length at B end)
S MD 5143: PIPE_INNER_DIAMETER_A_B
(inner pipe diameter A-B (nominal diameter))

S MD 5530: CYLINDER_SAFETY_CONFIG (protection circuit)

Drive data
S MD 5150: DRIVE_MASS (moved mass of drive)
S MD 5151: CYLINDER_A_ORIENTATION
(mounting position A end of cylinder)

S MD 5152: CYLINDER_FASTENING (cylinder mounting)

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3 Start-Up 02.99
3.7 Measuring system data

3.7 Measuring system data

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

To parameterize the encoder, one of the options “Incremental” or “Absolute”

(EnDat interface)” must be selected.
The value of the associated machine data is displayed as the scale graduation.
You can return to menu display “Mounting/supply data for HLA” by selecting
softkey “Back”.
Softkey “Ready” You can terminate the start-up operation for this drive by selecting softkey
“Ready”.
A dialog message then appears. This must be acknowledged with “Abort” or
“OK”.

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

You can return to menu display “Measuring system data for HLA” by selecting
softkey “Abort”.
When you press “OK”, the machine data are written to the drive. The drive
model and controller data are then calculated and the boot file saved. The pro-
gram then branches to the vertical softkey menu associated with softkey “Valve/
controller...” (see Fig. 3-5) in which the data can be checked and altered through
selection of “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.

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02.99 3 Start-Up
3.8 Changing data

3.8 Changing data

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

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

If you press “Abort”, the old machine data settings remain valid and you return
to the initial menu display (see Fig. 3-5).
Softkeys “Valve data...” , “Cylinder data...” and “Mounting data...” each call a
display that has the same format as the following screenshot except for display
header and contents (e.g. valve data for HLA):

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

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

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3 Start-Up 02.99
3.8 Changing data

The data entered for valve and cylinder and the mounting/supply data are used
to preset the following data when you activate “Calculate drive model data”.
These settings can be changed manually afterwards. It is advisable to confirm
the calculated model data by carrying out tests on the drive and correct them in
accordance 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 frequency of
drive A)
S MD 5163: DRIVE_NATURAL_FREQUENCY (natural frequency of drive)
S MD 5164: DRIVE_NATURAL_FREQUENCY_B (natural frequency of
drive B)
S MD 5231: FORCE_LIMIT_WEIGHT (weight force limitation)
S MD 5240: 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 const. 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)
S MD 5465: POS_DUAL_GAIN_COMP_VOLTAGE
(knee compensation pos. voltage)
S MD 5467: NEG_DUAL_GAIN_COMP_FLOW
(knee compensation neg. flow)
S MD 5468: NEG_DUAL_GAIN_COMP_VOLTAGE
(knee compens. neg. voltage)
S MD 5406: SPEEDCTRL_GAIN_A (velocity controller A P gain)
S MD 5407: SPEEDCTRL_GAIN (velocity controller P gain)
S MD 5408: SPEEDCTRL_GAIN_B (velocity controller B P gain)
S MD 5409: SPEEDCTRL_INTEGRATOR_TIME[n]
(velocity controller reset time)
S MD 5413: SPEEDCTRL_ADAPT_ENABLE (sel. of vel. controller adapt.)
S MD 5414: SPEEDCTRL_REF_MODEL_FREQ[n] (natural frequency of
reference model)
S MD 5415: SPEEDCTRL_REF_MODEL_DAMPING[n]
(damping of velocity controller reference model)
S MD 5430: SPEEDCTRL_PT1_TIME (smoothing time constant velocity lead
time)
S MD 5431: SPEEDCTRL_DIFF_TIME_A[n] (veloc. controller A lead time)
S MD 5432: SPEEDCTRL_DIFF_TIME[n] (velocity controller lead time)
S MD 5433: SPEEDCTRL_DIFF_TIME_B[n] (velocity controller B)

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3.8 Changing data

Controller data/ The modified machine data are transferred to the drive with “OK” (in Fig. 3-13)
Calculate drive and, depending on the option settings
model data S calculate drive model data and/or
S calculate controller data,
the dialog box “Calculate controller/drive model data” appears with the corre-
sponding text (see Fig. 3-15; in this case, for both options).

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

By pressing “Abort”, you can return to menu display “Change data for HLA” (see
Fig. 3-13).
When you press “OK”, the drive model data and/or controller data are calculated
again and you finally return to the initial menu display (see Fig. 3-5).
The filters, friction compensation and limitations can be parameterized to suit
the application afterwards.
Softkey “Help” displays a list of those machine data that are changed with soft-
key “OK”. In this case as well, the texts are dependent on the set options.

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

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3.9 Fine adjustment and optimization

3.9 Fine adjustment and optimization

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

3.9.1 Control direction, travel direction

General The control direction can be reversed by the following methods:

S Manipulated voltage
S Actual value inversion
S Scale rotation
S Piping A A to A B (inversion)
Any adjustment in the hydraulic piping can be cancelled by inversion of the ma-
nipulated voltage.
If the scale is rotated or attached at the wrong point (jacket or rod of cylinder),
the control direction can be adjusted by means of actual value inversion.

Limitation of The manipulated voltage must be limited before the system is first switched on
manipulated for a control direction check.
voltage MD 5475: OUTPUT_VOLTAGE_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, continue with 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
– Combinatorial connections of 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
When 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”.

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3.9 Fine adjustment and optimization

Start

no
Do MD 5706 and
MD 5707 (vset, vact)
Invert manipulated voltage MD 5476
have the same sign
when the drive starts?

yes, but fails with error message

Change MD 32110: ENC_FEEDBACK_POL (actual value sign)

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

Step 2

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

Definition of drive When the cylinder piston moves in the A B direction (flow Q > 0) , the actual
travel direction 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.
zwingend erforderlich.

Step 2 (adjust sign of actual velocity value)

Input a small positive valve manipulated voltage (function generator)

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

Invert control signal (change MD 5476 bit 0)

and
Is cylinder piston no invert actual value (change MD 5011 bit 0)
A traversing ! B and
and is MD 5707 change MD 32110: ENC_FEEDBACK_POL
positive? (actual value sign)

yes

Step 3

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

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3.9 Fine adjustment and optimization

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)

Step 3 (define travel direction of machine)

Traverse with JOG key

(override approx. 10%)

no MD 32100: Change AX_MOTION_DIR

Does cylinder move
in the set direction ? (travel direction of machine)

yes

End

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

Cancel The setpoint limitation must be set in MD 5475: OUTPUT_VOLTAGE_LIMIT to

manipulated 10 V.
voltage
limitation

3.9.2 Offset adjustment

Offset of pressure
sensors
Note
Only in combination with pressure sensing function.

Condition: Sensors are pressure-free!

Objective: The pressure display should be 0 at 0 pressure.
Adjustment:
S MD 5650: Set DIAGNOSIS_CONTROL_FLAGS bit 12 (cancelled automati-
cally after 2 s).
S Pressure sensor A:
MD 5551: PRESSURE_SENS_A_OFFS is automatically adjusted.
S Pressure sensor B:
MD 5553: PRESSURE_SENS_B_OFFS is automatically adjusted.
The display for the two pressures (MD 5704, MD 5705) should then show
about 0.0 bar.

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3.9 Fine adjustment and optimization

Reference value
for pressure
sensors Note
Only in combination with pressure sensing function.

Enter characteristic data of pressure sensors from data sheet in

S MD 5550: PRESSURE_SENS_A_REF (reference value for pressure sensor

A)

S MD 5552: PRESSURE_SENS_B_REF (reference value for pressure sensor

B)
according to data sheet.

Manipulated valve Objective: Adjustment of electro-hydraulic zero point

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

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

S In position-controlled mode at zero speed with all enabling signals applied

(drive can be traversed with JOG keys).

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.

3.9.3 Velocity compensation

Objective Owing to the tolerances of the valves and drive units with
S real areas
S real valve edge,
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

S MD 5435: CONTROLLED_SYSTEM_GAIN (stage 1)

and
S MD 5462: AREA_FACTOR_POS_OUTPUT/
MD 5463: AREA_FACTOR_NEG_OUTPUT (stage 2).
durchgeführt.
Controller parameters

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

S I: reset time of velocity controller (MD 5409)

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

must be set to 0.

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02.99
3.9 Fine adjustment and optimization

Adjustment of Use function generator to input a velocity setpoint of vset,

controlled system offset=0.
gain
Output curve behavior n1  n2 Objective of adjustment nvoff = 0
Controller=0; D, I, P nvon = 0

v
n1 vset

Cylinder vact
travel-out

t
Cylinder n2
travel-in

1st adjustment stage: Even adjustment for both velocity directions

with MD 5435; Make vset and vact congruent
at one end.

v vset
n1

Cylinder
vact
travel-out

t
Cylinder
travel-in n2 = 0

2nd adjustment stage: Direction-dependent adjustment with MD 5462

and/or nMD 5463.

v
n1 = 0

vset
Cylinder
travel-out
vact t

Cylinder n2 = 0
travel-in
3rd adjustment stage:

Fig. 3-20 Adjustment of controlled system gain

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 sys-
tem gain must be set or
– the gain can be adjusted to match the relevant operating range.
S Both methods of 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.

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3.9 Fine adjustment and optimization

3.9.4 Referencing data for HLA

Piston neutral The position of the cylinder piston is required for functions “Force controller” and
position “Velocity controller adaptation”. For this purpose, the piston position must be
adjusted once after referencing.
This is done by the following sequence of operations:

S Reference point approach

S Select softkey “Piston position” (see Fig. 3-5)
S Move cylinder piston to limit stop at A end
S Press softkey “Position adjust.” (see Fig. 3-21) to transfer the value set in
MD 5740: ACTUAL_POSITION to MD 5040: PISTON_ZERO.

S Save boot file

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

Select softkey OK to return to the initial menu display for the HLA.
The following machine data are relevant to the adjustment of the piston position:

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

S MD 5740: ACTUAL_POSITION (actual position in relation to machine zero)
S MD 5741: ACTUAL_PISTON_POSITION (piston position in relation to piston
zero)

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

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3 Start-Up 02.99
3.9 Fine adjustment and optimization

3.9.5 Controller optimization

General The most important travel motions are converted via the feedforward control
path.
The function of the controller parameters is to dampen the oscillation character-
istics of the valve/cylinder grouping.
In this respect, three different scenarios relating to the corner frequency (f) must
be distinguished:
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 dampened.

Amplitude log frequency curve

101 Valve:
fv=100 Hz; Dv=0.8
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

Phase frequency curve

–90
Phase angle

–180

–270

101 102 103

log f

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

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3.9 Fine adjustment and optimization

2. fvalve
fcylinder (f)

Amplitude log frequency curve

101 Valve:
fv=100 Hz; Dv=0.8
100
Drive:
fa=100 Hz; Da=0.1
10–1

log value 10–2

10–3

10–4

10–5
101 102 103
log f

Phase frequency curve

–90
Phase angle

–180

–270

101 102 103

log f

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

fcylinder)

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3 Start-Up 02.99
3.9 Fine adjustment and optimization

3. fvalve >> fcylinder (f)

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

Amplitude log frequency curve

101
Valve:
fv=100 Hz; Dv=0.8

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

Phase frequency curve

–90
Phase angle

–180

–270

101 102 103

log f

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

The controller components are optimized in the following order:

1. P component (proportional component)
2. D component (derivative component)
3. I component (integral component)
The preferred method of optimization uses unit step functions (step response)
with the function generator (FG) through the input of a velocity setpoint vset.
The measuring function with noise signals (FFT, PBRS) may be difficult to inter-
pret owing to non-linearities in the controlled system.
The causes for deviations in the characteristic data are as follows:
S Theor. Valve: Real valve
S Pipework: Control pressure = f(Q)
S Additional valves; Shutoff valves; filters; throttles (pressure measuring
plates)

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3.9 Fine adjustment and optimization

Optimization of Relevant machine data:

controller P
MD 5406: SPEEDCTRL_GAIN_A (P gain of velocity controller A)
component MD 5407: SPEEDCTRL_GAIN (P gain of velocity controller)
MD 5408: SPEEDCTRL_GAIN_B (P gain of velocity controller B)
The theoretical characteristic data of the valve and cylinder are used to calcu-
late a suggested P gain value. The positive feedback area (MD 5406...MD 5408
<0) is included in the calculation to damp the drive system.
The adjustment to real conditions on the machine (special damping require-
ments) should be made according to the following criteria:
1. P component must be as positive as possible.
Optimization direction
MD 5406
MD 5407
<0 0 >0 MD 5408

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

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

Threshold values (typical):

S f
P>0
S f P<0, or around zero
S f P>0
(f
...f see Section 3.9.5 paras. 1...3)

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

Optimization of Relevant machine data:

controller D
MD 5431: SPEEDCTRL_DIFF_TIME_A (Lead time TV of velocity controller A)
component MD 5432: SPEEDCTRL_DIFF_TIME (Lead time TV of velocity controller)
MD 5433: SPEEDCTRL_DIFF_TIME_B (Lead time TV of velocity controller B)
MD 5430: SPEEDCTRL_PT1_TIME (velocity controller smoothing time
constant)
The positive phase displacement of the derivative term can be utilized to ac-
tively dampen the controlled system for f type.
The derivative-action time constant/corner frequency must be parameterized to
values higher than the minimum natural frequency of valve and drive.

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3 Start-Up 02.99
3.9 Fine adjustment and optimization

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
)
The smoothing time constant is set to values  1 ms as a function of the con-
trolled system for “calculate controller”.
Owing to the fact that a derivative action amplifies the actual value noise, it is
necessary in this case to find a compromise between

S the derivative action (and thus vibration damping)

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

S the noise of the manipulated variable.

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 TV0, in most
cases TV=0 is the best choice.

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

Optimization of
controller I S Integrator/reset time (TN)
component
Objective: Elimination of errors in feedforward control channel.
Implementation: TN>5 ms, taking the overshoot behavior
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).

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3.9 Fine adjustment and optimization

3.9.6 Controller adaptation

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 Preconditions:

S NC end has been referenced.

S Cylinder piston in neutral position has been adjusted according to Section
3.9.4.

S Control parameters have been processed according to the relevant operat-

ing range.
Procedure:

S Optimize the velocity controller (P and D components) with the associated

machine data at the limits and at position set in MD 5160.
Example: (cf. Fig. 4-10) operating range = total piston stroke
Interpolation point 1 Optimization to A end of cylinder
MD 5406: SPEEDCTRL_GAIN_A (P gain)
MD 5431: SPEEDCTRL_DIFF_TIME_A (D gain)
Interpolation point 2 Optimization to piston position as set in
MD 5160: PISTON_POS_MIN_NAT_FREQ
MD 5407: SPEEDCTRL_GAIN (P gain)
MD 5432: SPEEDCTRL_DIFF_TIME (D gain)
Interpolation point 3 Optimization to B end of cylinder
MD 5408: SPEEDCTRL_GAIN_B (P gain)
MD 5433: SPEEDCTRL_DIFF_TIME_B (D gain)

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

S Velocity controller adaptation active

MD 5413: SPEEDCTRL_ADAPT_ENABLE=1

Note
SPEEDCTRL_ADAPT_ENABLE=1 (MD 5413) is switched through only
when the axis has been referenced and adjusted.
With f
(see Section 3.9.5), adaptation is deactivated during “Calculate
controller data”.

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3 Start-Up 02.99
3.9 Fine adjustment and optimization

3.9.7 Hydraulic/electrical interpolation

Objective Contour accuracy between hydraulic and electrical drives is achieved when the
drive dynamic response is set identically on the involved axes.
In addition to identical servo gain settings, it must be ensured that the step re-
sponse of the closed speed controller is “identical”.

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

v
vact, el

vw
vact, hyd

0.5

Teqv, el Teqv, hyd t

Fig. 3-25 Hydraulic/electrical interpolation

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

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3.10 File functions

3.10 File functions

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

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

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

Fig. 3-27 Menu display “File functions”

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3 Start-Up 02.99
3.11 Start-up functions

3.11 Start-up functions

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

S Measuring functions
– Measurement of valve control loop
– Measurement of velocity control loop
– Measurement of position control loop

S function generator,
S Circularity test
S Servo trace
S DAC configuration

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

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

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04.00
02.99 3 Start-Up
3.11 Start-up functions

3.11.1 Measurement function

The measurement functions allow assessment of the most important variables

of the speed and position control loop in the time and frequency range without
the use of external measuring devices on the screen.
An Overview of the measurement functions provided for HLA is given below,
with only the purely hydraulic-specific functionality for HLA described in detail.
The following measuring functions can be performed in conjunction with the
HLA:

S Valve control loop measurement

– Valve frequency response

S Velocity control loop measurement

– Reference frequency response
– Setpoint step change
– Interference frequency response
– Disturbance step change
– Velocity path
– Velocity path + controller

S Position control loop measurement

– Reference frequency response
– Setpoint step change
– Setpoint ramp

Valve control loop

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

Measurement Trigger Measured quantities

Valve frequency Valve spool setpoint in velocity con- Actual valve spool value/
response troller cycle, valve control loop closed, valve spool setpoint
velocity control loop open

Table 3-3 Parameterization of valve control loop measurement

Parameter Physic. Unit

Amplitude typ 1 V V
Bandwidth typ 1000 Hz Hz
Averaging operations typ 10 –
Settling time typ 100 ms
Offset typ 0 V

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

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3 Start-Up 04.00
02.99
3.11 Start-up functions

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 Example of valve frequency response on HRV size 06, 15 l/min, knee-point
60%. Note: For setting of valve data, see Section 4.7.

Measurement
Velocity control
loop Table 3-4 Measurement types and quantities for measurement of velocity control
loop

Measure- Trigger Measured quantities

ment
Reference Velocity setpoint in velocity controller Actual velocity value/
frequency re- cycle, valve control loop closed, velocity velocity setpoint
sponse control loop closed
Setpoint step Velocity setpoint in velocity controller Quantity 1:
change cycle, valve control loop closed, velocity S Velocity setpoint
control loop closed
S Valve spool setpoint
Quantity 2:
Actual velocity value
Interference Valve spool setpoint in velocity controller Actual velocity value/
frequency re- cycle, valve control loop closed, velocity valve spool setpoint
sponse control loop closed
Disturbance Valve spool setpoint in velocity controller Quantity 1:
step change cycle, valve control loop closed, velocity Valve spool setpoint
control loop closed Quantity 2:
Actual velocity value
Velocity con- Valve spool setpoint in velcoity controller Actual velocity value/
troller path cycle, valve control loop closed, velocity actual valve spool value
control loop closed
Velocity con- Velocity setpoint in velocity controller Actual velocity value/
troller path + cycle, valve control loop closed, velocity control deviation
controller control loop closed

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3.11 Start-up functions

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

Parameter Physical Unit

Reference frequency response
Amplitude (linear axis) mm/min | inch/min
Bandwidth Hz
Averaging operations –
Settling time ms
Offset (linear axis) mm/min | inch/min
Setpoint step change
Amplitude (linear axis) mm/min | inch/min
Measuring time ms
Settling time ms
Offset (linear axis) mm/min | inch/min
Disturbance step change
Amplitude V
Measuring time ms
Settling time ms
Offset (linear axis) mm/min | inch/min
Velocity controller path
Amplitude V
Bandwidth Hz
Averaging operations –
Settling time ms
Offset (linear axis) mm/min | inch/min
Velocity controller path + controller
Amplitude (linear axis) mm/min | inch/min
Bandwidth Hz
Averaging operations –
Settling time ms
Offset (linear axis) mm/min | inch/min

The following functional response in the diagrams were recorded with the equip-
ment combination below:
Valve: HRV size 06, 15 l/min, knee-point 60 %

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3.11 Start-up functions

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

0.000 t [ms] 50.000

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

Step change: 0 → 100 mm/min without closed-loop force control, real friction
conditions
Trace 1: Velocity setpoint
Trace 2: Actual velocity value

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02.99 3 Start-Up
3.11 Start-up functions

0.100 t [ms] 100.000

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

Trace 1: Valve spool setpoint

Trace 2: Actual velocity value

90.000

Ampl.
[dB]

10.000
1.000 log [Hz] 1000.000
180.000

Phase
[degrees]

–180.000

1.000 log [Hz] 1000.000

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

Note: Phase crossover -90 degrees essentially characterizes the

cylinder natural frequency

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 3-83
3 Start-Up 02.99
3.11 Start-up functions

20.000
Amplitude margin at 180 degrees
0
Ampl.
[dB]

–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

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

Note: Measurement of open velocity controlled system,

indicative of the stability of the control loop.
Target values for stability of control loop:

S At least 3 dB amplitude margin at 180 degrees

S At least 60 degrees phase margin at 0 dB

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

Measurement Trigger Measured quantities

Reference fre- Position setpoint in position control- Actual position/position set-
quency response ler cycle, position control loop point
closed, velocity control loop closed
Setpoint step Position setpoint in position control- Quantity 1:
change ler cycle, position control loop Position setpoint
closed, velocity control loop closed Quantity 2:
S Actual position
Setpoint ramp S Control deviation
S Following error
S Actual velocity

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3-84 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.11 Start-up functions

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

Parameter Physic. Unit

Reference frequency response
Amplitude (linear axis) mm | inch
Bandwidth Hz
Averaging operations –
Settling time ms
Offset (linear axis) mm/min | inch/min
Setpoint step change
Amplitude (linear axis) mm | inch
Measuring time ms
Settling time ms
Offset (linear axis) mm/min | inch/min
Setpoint ramp
Amplitude (linear axis) mm | inch
Measuring time ms
Ramp duration ms
Settling time ms
Offset (linear axis) mm/min | inch/min

20.000

Ampl.
[dB]

-60.000
0.100 log [Hz] 125.000

180.000

Phase
[degrees]

–180.000
0.100 log [Hz] 125.000

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

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 3-85
3 Start-Up 02.99
3.11 Start-up functions

3.11.2 Function generator

The function generator for HLA is based on the existing functionality provided
for other drive types integrated to date. The functionality for HLA, which is not
especially designed for hydraulic drives, is based on the SLM range of func-
tions.
The function generator excites the drive with a periodic signal. The signal type
is a parameterizable quantity. External measuring instruments such as oscillo-
graphs can register the system reactions via DAC output jacks.
The following signals (operating modes) and signal types are available on the
HLA:
S Signals (operating modes)
– Valve spool setpoint
– Velocity setpoint
– Position setpoint
S Signal type
– Square-wave
– Noise signal (only for signal output via DAC and external evaluation
equipment for frequency response analyses)

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

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

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3-86 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.11 Start-up functions

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

References: /BF/, DD. “Speed Control Loop”
/TIM/, SIMODRIVE 611 “Manual for MK 172A”
An Overview of the function generator functions provided for HLA is given be-
low, with only the purely hydraulic-specific functionality for HLA described in
detail.

Valve spool
setpoint (manipu-
Table 3-8 Signal (operating mode) for valve spool setpoint
lated voltage)
Trigger Signal type
Valve spool setpoint in velocity controller cycle, valve Square-wave
control loop closed, velocity control loop open

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

Parameter Physical Unit

Signal type: Square-wave
Amplitude V
Period ms
Pulse width ms
Offset V
Limitation V

Tr. 1: Valve stroke setpoint

Tr. 2: Actual valve stroke
1.9890
2.0510

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 set-
point

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3 Start-Up 02.99
3.11 Start-up functions

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

Trigger Signal type

Velocity setpoint in velocity controller cycle, valve control Square-wave
loop closed, velocity control loop closed

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

Parameter Physical Unit

Signal type: Square-wave
Amplitude (linear axis) mm/min | inch/min
Period ms
Pulse width ms
Offset (linear axis) mm/min | inch/min
Limitation (linear axis) mm/min | inch/min

Note
The following diagram was created using a servo trace.

0.000 t [ms] 2.000e+03

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

Amplitude: 100 mm/min

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02.99 3 Start-Up
3.11 Start-up functions

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

Trigger Signal type

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

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

Parameter Physical Unit

Signal type: Square-wave
Amplitude (linear axis) mm | inch
Period ms
Pulse width ms
Offset (linear axis) mm/min | inch/min
Limitation (linear axis) mm | inch

Note
The following diagram was created using a servo trace.

0.000 t [ms] 2.000e+03

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

Amplitude: 100 mm

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3 Start-Up 04.00
02.99
3.11 Start-up functions

3.11.3 Circularity test

The circularity test is used among other things as a way of checking the result-
ing contour precision. The actual positions of a circular movement are mea-
sured and the deviations from the programmed radius (especially at quadrant
transition points) displayed graphically. For detailed information, see:
References: /FB/ Part 2, K3, Sect. 2.7 “Circularity test”
Example: The following example refers to a drive with an HRV.
X1 axis: Horizontal movement by electrical drive
Y1 axis: Vertical movement by hydraulic drive

Tr. 1: X1 axis: Circularity test (electrical axis)

Tr. 2: Y1 axis: Circularity test (hydraulic axis)

Scl/Div = 1.000e–03 Radius = 19.999

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

3.11.4 Servo trace

The servo trace function is used for graphic representation of signals and oper-
ating conditions.
A hydraulic-specific signal list (servo and drive signals) is available as a support
function for axes with HLA module.
The following hydraulic-specific drive signals are supported by the servo trace:
S Active power (with pressure sensing)
S Actual force (with pressure sensing)
S Actual velocity value
S Valve stroke setpoint
S Actual valve stroke
S Actual pressure cylinder A end
S Actual pressure cylinder B end

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3-90 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.11 Start-up functions

3.11.5 DAC parameterization

For DAC measuring sockets see Section 5.1.5.

Fig. 3-42 Menu display “DAC parameterization”

DAC selection list

Table 3-14 DAC selection list

Designation Unit
Pressure p(A) (with pressure sensing) bar
Pressure p(B) (with pressure sensing) bar
Actual value spool value V
Valve spool setpoint V
Actual velocity value mm/min
velocity Setpoint (at filter input) mm/min
velocity Setpoint (limited at filter output) mm/min
velocity Reference model setpoint mm/min
Actual force (with pressure sensing) N
Active power (with pressure sensing) kW
Control deviation of velocity controller mm/min
Velocity controller P component V
Velocity controller I component V
Velocity controller D component V
Feedforward control component velocity controller V
Friction feedforward control component velocity controller V
Velocity controller output before filter V
Velocity controller output after filter V
Actual position mm
Force setpoint N
Force controller control deviation N

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 3-91
3 Start-Up 02.99
3.11 Start-up functions

Table 3-14 DAC selection list

Designation Unit
Force controller P component V
Force controller I component V
Force controller D component V
Feedforward control component force controller V
Force controller output V
Zero marker signal –
BERO signal –
Physical address (drive) –

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3-92 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.12 User views

3.12 User views

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

Fig. 3-43 Menu display “Edit view”

3.13 Display options

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

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

Fig. 3-44 Menu display “Display options”

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 3-93
3 Start-Up 04.00
02.99
3.14 Configuring an OEM-valve list

3.14 Configuring an OEM valve list

General OEM users can add their own valves to the valve list by copying file ibhlvlvo.ini
into directory “\oem”. This list is added as a separate item under the heading
“OEM valves” at the end of the system list (Siemens list).
The syntax of the valve list is identical to that of a Windows INI file. The list can
be drawn up under “Start-up”, “MMC”, “Editor”.
Mark C:\OEM, “new”, enter filenameibhlvlvo.ini , “Ok”.

Format This file must be formatted as follows:

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

Example of an
OEM valve list

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
[DATA]

ÁÁÁÁÁÁ
;5106
ÁÁÁÁÁÁÁÁ
ÁÁÁ
,
ÁÁÁÁÁÁÁÁ
,
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
,
ÁÁÁÁ
5107, 5108 5109 5110 5111 5112 5113, 5114 5115 , ,

ÁÁÁ
ÁÁÁ ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
, , , , , , ,

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
1001= OEM, 01, Size 90.1, 5, 10, 10, 39.8, 1) 0001B, 35, 1.0, 90, $T740,
16,

ÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁ
Á ÁÁ
ÁÁ
Á ÁÁÁ
1050= OEM,
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
02,
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
Size
ÁÁÁÁ40.2, 5, 10, 10, 40.1, 1) 0001B, 35, 1.0, 40, $T740,

ÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
Á ÁÁÁ
10,

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
1051= OEM, 03, HRV1, 8.1, 35, 10, 10, 10, 1) 0000B, 200, 0.8, 8, $T8,

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁ
1030= OEM, 04, Size 100.1, 35, 10, 10, 38.5, 2, 0010B, 70, 0.8, 100, $T740,
10,
$L= “End of list”
$L= “– – – – – – – – –”

Note
Columns 1 and 2 are separated by an “=” symbol, all other columns by a
comma. Column 15 is ended by a comma.
An MMC Reset must be performed to make changes effective.

 Siemens AG 2000. All rights reserved

3-94 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 3 Start-Up
3.14 Configuring an OEM-valve list

ÁÁÁÁÁÁÁÁÁÁÁ
Table 3-15
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Meaning of individual columns

ÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Col- Description Column in Reference to MD Unit
umn in MMC dis-

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁ
OEM play
valve Name No.

ÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁ
list

ÁÁÁÁÁÁÁÁ
1 ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
Valve code no.
ÁÁÁÁ 7 VALVE_CODE 5106

ÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
2 Manufacturer’s name 1

ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
3 Order No. 2

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
4 Designation 3

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
5 Rated valve flow VALVE_NOMINAL_FLOW 5107 [l/min]

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
6 Rated pressure drop of VALVE_NOMINAL_PRESSSURE 5108 [bar]
valve

ÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
7
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
8
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
Rated voltage of valve

ÁÁÁÁ
ÁÁÁÁ
Valve knee-point voltage
VALVE_NOMINAL_VOLTAGE
VALVE_DUAL_GAIN_FLOW
5109
5110
[V]
[%]

ÁÁÁÁÁÁÁÁÁÁÁ
9
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
10 ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
Knee-point voltage of valve

ÁÁÁÁ
ÁÁÁÁ
Rated flow rate ratio be- 6
VALVE_DUAL_GAIN_VOLTAGE
VALVE_FLOW_FACTOR_A_B
5111
5112
[%]

ÁÁÁ
ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ
tween A and B ends of valve

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
11 Valve configuration VALVE_CONFIGURATION 5113

ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Á ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
12 Natural frequency of valve VALVE_NATURAL_FREQUENCY 5114 [Hz]
13 Valve damping VALVE_DAMPING 5115
14 Rated valve flow for display 4 [l/min]
15 Valve knee-point voltage for 5 [%]
display

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.

S The following applies to the display (selection list) on the MMC:

The character strings used are identical to those stored in the INI file.

S The following applies to writing machine data:

– Unless otherwise specified, the decimal format is always used. If the
number is followed by a capital B, it is interpreted as a binary number. If
a capital H is inserted after the number, it is interpreted as a hexadecimal
value.
– Floating-point numbers must be specified in US format (decimal
point=“.”) and WITHOUT the separator symbol for 1000s (“,”).
– The individual fields in this section can be left empty, i.e. they contain 2
commas one after the other or two blanks between the 2 commas.
Empty fields are not written to the drive, i.e. the default setting of the ma-
chine data is transferred unchanged. The number of blanks is optional.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 3-95
3 Start-Up 02.99
3.14 Configuring an OEM-valve list

Language-
dependent texts
Any language-dependent texts can be inserted in the OEM valve list. These all
start with $T.
Syntax: $T<X> (no dash dot)
In this case, <X> refers to a text in the language-dependent
text files
(see also language-dependent OEM texts)
Subheadings can also be inserted in the OEM valve list by adding the instruc-
tion “$L=<beliebiger 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 system be used in OEM valve lists.
texts $T1=Order No.;
$T2=Name;
$T3=Rated flow;
$T4=Knee-point voltage;
$T5=Rated flow A:B;
$T6=Code;
$T7=“ Knee”;
$T8=“ Linear”;
$T9=Company;
$T10=Unlisted valve;
$T11=l/min;

Language- Language-dependent OEM display texts are stored in directory \oem\language

dependent OEM in files \ibdrv_<SPRACHE>.ini
texts < SPRACHE > stands for the appropriate language code. This file would be
named ibdrv_gr.ini for German. The codes for all languages installed in a sys-
tem are listed in file \mmc2\mmc.ini, section [LANGUAGE], entry LanguageL-
ist. Language-dependent OEM text files must be formatted as follows:
[TEXT]
$T<X>=<beliebiger Text>;
:<X> is any number 1000 and
32767, that must only occur once.

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

J

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3-96 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Firmware Drive Functions 4
4.1 Block diagram of closed-loop control

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

Control system HLA module Drive

Actual position
Cylinders
Velocity feedforward Flow feedforward control
control v’vor
Character-
Position set-Position
istics com- Valve setpoint voltage
point xset controller
pensation Uset
D
A
Velocity setpoint Velocity controller
P P
vset U U

Actual Actual velocity vact pA

position pB
xact
A B Servo solenoid valve

P T
Valve amplifier

Pressure supply

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

Achievable Dynamic response is dependent upon:

dynamic response S Natural frequency of the servo solenoid valve (see Section 2.3.2)
S Natural frequency of the drive (see Section 2.3.4)
The greater the natural frequency, the better the achievable dynamic response.
For the purpose of oscillation damping, the natural frequency of the servo sole-
noid valve must be greater than that of the drive.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 4-97
 Friction injection
MD 5460/MD 5461

4-98
Fig. 4-2
Control output filter
Flow 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
Block diagram of

limitation Velocity controller ation

control functions

MD 5506/MD 5507/ compensation Manipulated voltage

MD 5514–MD 5516/ MD 5440/ P component MD 5200–MD 5205/ MD 5462 Selection MD 5464–MD 5468
limitation
MD 5520/MD 5004 MD 5441 MD 5406–MD 5408 MD 5210–MD 5215 MD 5463 logic MD 5480–MD 5488 MD 5475

Adaptation
4 Firmware Drive Functions

Reference to
Velocity model DAC
Setpoint vset MD 5414/ I component
MD 5415 MD 5421/MD 5422

Offset
4.1 Block diagram of closed-loop control

Limitaton
Actual velocity v act control
D component
MD 5430–MD 5433
Adaptation

Controllers andcharacteristic functions of HLA module

Actual position x act

Feedforward control filter

Force controller Feedforward control factor Area adapt-
MD 5230–MD 5235 MD 5247 ation MD 5260/5261
MD 5241 (configuration) MD 5264/5265/MD 5268-MD 5270
Adaptation
Attenuation
P component (valve dynamic response)
F MD 5242 MD 5243
set
characteristics that is implemented in the HLA module.

Adaptation
I component
MD 5244

D component
MD 5245/MD 5246
Adaptation
F
act (see Section 4.4, Fig. 4-11) only if pressure sensor is connected
Fig. 4-2 shows the functionality for velocity and closed-loop force control plus
04.00
02.99

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02.99 4 Firmware Drive Functions
4.2 Functions

4.2 Functions

4.2.1 Overview of functions

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

S Velocity feedforward control (Section 4.3.1)

– Controlled system gain
– Velocity setpoint filter
– Setpoint limitations

S Velocity controller (Section 4.3.2)

– P/D/I components
– Adaptation
– Integrator feedback
– Reference model
– Control output filter in velocity controller

S Closed-loop force control (Section 4.4)

– P/D/I components
– Force limitations
– Controlled system gain

S Manipulated voltage output (Section 4.5)

– Characteristic compensation
– Control output filter
– Manipulated voltage limitations

4.2.2 System environment

Parameter set A parameter set changeover function involving 8 different parameter sets has
changeover been implemented. The request is made via the PLC. They are predominantly
controller and filter data that can be switched over as a function of parameter
set.
Data which are assigned to specific parameter sets are identified by an [n] in the
string code.
Parameter set assignments can be found in the parameter table (Section 4.15)
in the “Attribute index” column with entries 0...7.

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02.99
4.3 Closed-loop velocity control

4.3 Closed-loop velocity control

4.3.1 Velocity adaptation/feedforward control

Velocity setpoint The NC drive transfer interface is normalized to the maximum velocity set in
adaptation data MD 5401: DRIVE_MAX_SPEED.

5401 DRIVE_MAX_SPEED Cross ref.: –

Maximum useful velocity Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 0.0 0.0 120 000.0 FLOAT Power On

The velocity limit is defined by the settings in MD 5440:

POS_DRIVE_SPEED_LIMIT and MD 5441: NEG_DRIVE_SPEED_LIMIT, but
not with MD 5401: DRIVE_MAX_SPEED.

Velocity setpoint
interpolation

5004 CTRL_CONFIG Cross ref.: –

Configuration structure Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 1000 0 1000 UNS.WORD Power On

Velocity setpoints are input in the position controller cycle.

In order to prevent rigorous drive positioning motions at the beginning of each
position controller cycle, the current and previous velocity setpoint are interpo-
lated linearly in the drive.
Bit 12=0: No interpolation, velocity setpoint changes only in the position
controller cycle.
Bit 12=1: Linear interpolation of velocity setpoint over one position
controller cycle. The default setting is active.

Velocity Velocity setpoint interpolation deactivated

setpoint
Velocity setpoint from the
NC
Velocity setpoint active in
drive
Time
Position
controller cycle
Velocity Velocity setpoint interpolation activated
setpoint

Time
Position controller cycle

Fig. 4-3 Velocity setpoint interpolation

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4.3 Closed-loop velocity control

Velocity setpoint Due to the complexity of applying velocity setpoint filters, no generally applica-
filters ble, definitive guidelines for their use can be given here. However, criteria for
selecting filters and their parameters are defined below.
The purpose of velocity setpoint filters is to adapt the velocity-controlled drive
grouping to the higher-level position control loop. Band-stop and low-pass filters
(PT2/PT1) are available.
The task of a filter is to
S smooth the control response characteristic,
S dampen 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 compen-
sate 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.
The input of damping values close to the minimum input limits results in over-
shoots up to a factor of 2 in the time range.

5500 NUM_SPEED_FILTERS [n] 0...7 index of the parameter set Cross ref.: –
No. of velocity filters Relevant for: Protection level:
0: No velocity filter active HLA 3/3
1: Velocity filter activated
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 1 UNS.WORD Immediately
5501 SPEED_FILTER_TYPE [n] 0...7 index of the parameter set Cross ref.: –
type of velocity filter Relevant for: Protection level:
Bit 0= 0: Low-pass (see MD 5502, MD 5506, MD 5507) HLA 3/3
1: Band-stop (see MD 5514 – MD 5516, MD 5520)
Bit 8= 0: PT2 low-pass (see MD 5506, MD 5507)
1: PT1 low-pass (see MD 5502)
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 257 UNS.WORD Immediately
5502 SPEED_FILTER_1_TIME [n] 0...7 index of the parameter set Cross ref.: –
PT1 time constant for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 parameterized
in MD 5501 as a PT1 or PT2 low-pass or as a band-stop filter. The key data for
the filter are set in MD 5502 to MD 5520.
The filter is deactivated if machine data MD 5502 is set to 0.

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4.3 Closed-loop velocity control

5506 SPEED_FILTER_1_FREQUENCY [n] 0...7 index of the parameter set Cross ref.: –
PT2 natural frequency for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 2000.0 10.0 8000.0 FLOAT Immediately
5507 SPEED_FILTER_1_DAMPING [n] 0...7 index of the parameter set Cross ref.: –
PT2 damping for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 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
With reference to interpolating axes, please read Section 3.9.7.

Amplitude log 10
frequency curve 0.2
3
0 0.5
–3
Absolute 1.0
value –10
[dB]
–20

–30
102 103 log f [Hz]

Phase frequency Natural frequency

curve 180

90
Phase angle
[degrees] 0
1.0
–90 0.5
0.2
–180
102 103 log f [Hz]

Fig. 4-4 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

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4.3 Closed-loop velocity control

5514 SPEED_FILTER_1_SUPPR_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Band-stop filter blocking frequency for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 3500.0 10.0 7999.0 FLOAT Immediately
5515 SPEED_FILTER_1_BANDWIDTH [n] 0...7 index of the parameter set Cross ref.: –
Band-stop filter bandwidth for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 500.0 5.0 7999.0 FLOAT Immediately

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

5516 SPEED_FILTER_1_BW_NUMERATOR [n] 0...7 index of the parameter set Cross ref.: –
Numerator bandwidth for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 ref.: –
Band-stop filter natural frequency for velocity filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 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 value
fo two velocity controller cycles
(MD 55200.01MD 5514<1/(2MD 500131,25 µs).

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4.3 Closed-loop velocity control

Amplitude log 10
frequency curve
500 Hz 1000 Hz 2000 Hz
3
0
Absolute –3
value
[dB] –10

–20

–30
102 103 log f [Hz]

Phase frequency
curve
180

Phase angle 90
[degrees]
0

–90
500 Hz 1000 Hz 2000 Hz
–180
102 103 log f [Hz]

Fig. 4-5 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
0
Absolute –3
value 500 Hz
[dB] –10
1000 Hz
–20

–30
102 103 log f [Hz]

Phase frequency
curve 180

Phase angle 90
[degrees] 100 Hz
0

–90
1000 Hz
500 Hz
–180
102 103 log f [Hz]

Fig. 4-6 Frequency response of undamped band-stop at a blocking frequency of 1000

Hz and variations in bandwidth (MD 5515) of 100 Hz, 500 Hz, 1000 Hz.
The bandwidth is the difference between the two frequencies with 3 dB drop in
amplitude.

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4.3 Closed-loop velocity control

Amplitude log 10
frequency curve
3
0
–3
Absolute 250
value –10 150
[dB]
0
–20

–30
102 103 log f [Hz]

Phase frequency
curve 180

90 150
Phase angle
[degrees]
0
250
–90
0
–180
102 103 log f [Hz]

Fig. 4-7 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
0
Absolute –3
value 1000
[dB] –10

707
–20

–30
102 103 log f [Hz]

Phase frequency
curve 180
1414
Phase angle 90
[degrees] 1414 1000
0

–90 707
707
–180
102 103 log f [Hz]

Fig. 4-8 Frequency response of general band-stop at a blocking frequency of fz=1000

Hz, bandwidth fBn=500 Hz, numerator bandwidth fBz=0 Hz and variation in
natural frequency of (MD 5520) fn=70.7 %, 1000 % and 141.4 %

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4.3 Closed-loop velocity control

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.

5420 DRIVE_MAX_SPEED_SETUP Cross ref.: –

Max. velocity for setup mode Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 10.0 0.0 120 000.0 FLOAT Immediately
5440 POS_DRIVE_SPEED_LIMIT Cross ref.: –
Positive velocity setpoint limit Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 0.0 0.0 120 000.0 FLOAT Immediately
5441 NEG_DRIVE_SPEED_LIMIT Cross ref.: –
Negative velocity setpoint limit Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 0.0 0.0 120000.0 FLOAT Immediately

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 ZK3 message (can be interrogated via PLC) is activated when
the limitation 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 preset
accordingly.

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

Controlled system The controlled system gain should be entered in MD 5435 after “Calculate drive
gain model data” and not 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 ref.: –
Controlled system gain Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/Vmin 0.0 0.0 20000.0 FLOAT Immediately

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4.3 Closed-loop velocity control

Friction
5460 FRICTION_COMP_GRADIENT Cross ref.: –
Gradient of friction compensation characteristic Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 0.0 400.0 FLOAT Immediately
5461 FRICTION_COMP_OUTPUT_RANGE Cross ref.: –
Effective range of friction compensation (at output) Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.1 0.1 10.0 FLOAT Immediately

In order to reduce the effects of friction, the characteristic gradient is made

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

Output

100%
MD 5461
MD 5460
–100%
Input
100%

– MD 5461
–100%

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

4.3.2 Velocity controller

Velocity controller Sampling time with which the velocity control loop is calculated.
cycle

5001 SPEEDCTRL_CYCLE_TIME Cross ref.: –

Velocity controller cycle Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
31.25 µs 4 2 16 UNS.WORD Power On

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

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4.3 Closed-loop velocity control

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

Adaptation of Adaptation of the P and D components is recommended in cases where the

P and D natural frequency of the servo solenoid valve is higher than that of the drive.
components
5413 SPEEDCTRL_ADAPT_ENABLE Cross ref.: –
Selection of velocity controller adaptation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 1 UNS.WORD Immediately

Precondition: Adaptation can be selected only zero calibration of cylinder piston,

see Section 3.9.4.
The adaptation is activated (bit 0=1) or deactivated (bit 0=0) depending on the
setting in MD 5413: SPEEDCTRL_ADAPT_ENABLE. If adaptation is deacti-
vated, machine data MD 5407: SPEEDCTRL_GAIN and MD 5430:
SPEEDCTRL_PT1_TIME apply.

S Adaptation ON (see Fig. 4-10)

MD 5406: SPEEDCTRL_GAIN_A and MD 5408: SPEEDCTRL_GAIN_B are
programmed to define the P gain and MD 5431:
SPEEDCTRL_DIFF_TIME_A and MD 5433: SPEEDCTRL_DIFF_TIME_B
to define the derivative-action time (D component) at the A and B ends of
the cylinder.
MD 5407: SPEEDCTRL_GAIN and MD 5432: SPEEDCTRL_DIFF_TIME
act on the position set in MD 5160: PISTON_POS_MIN_NAT_FREQ.

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.

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4.3 Closed-loop velocity control

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
Natural 0 MD 5160 MD 5134
frequency
of drive

MD 5162
MD 5164

MD 5163

Piston position
0 MD 5160 MD 5134
(min. natural frequency) (piston stroke)
Piston end Piston end
Cylinder A end Cylinder B end

A B A B

Fig. 4-10 Adaptation

P component

5406 SPEEDCTRL_GAIN_A [n] 0...7 index of the parameter set Cross ref.: –
P gain of velocity controller A Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 –100.0 1000.0 FLOAT Immediately
5407 SPEEDCTRL_GAIN [n] 0...7 index of the parameter set Cross ref.: –
P gain of velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 –100.0 1000.0 FLOAT Immediately
5408 SPEEDCTRL_GAIN_B [n] 0...7 index of the parameter set Cross ref.: –
P gain of velocity controller B Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 –100.0 1000.0 FLOAT Immediately

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4.3 Closed-loop velocity control

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 the full rated valve voltage is output as the P compo-
nent with a setpoint/actual value difference corresponding to maximum velocity
(MD 5440: POS_DRIVE_SPEED_LIMIT, MD 5441:
NEG_DRIVE_SPEED_LIMIT).
The P gain set in MD 5407 SPEEDCTRL_GAIN is referred to the 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 ref.: –
Reset time of velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 50.0 0.0 2000.0 FLOAT Immediately

The integral-action component can be deactivated by setting the reset time to

zero. With a negative P gain setting, the reset time is interpreted as a negative
value so that the compensation always acts as negative feedback.
The integrator can be activated/deactivated via the PLC. The current status is
returned to the PLC.

Integrator
feedback

5421 SPEEDCTRL_INTEGRATOR_FEEDBK [n] 0...7 index of the parameter set Cross ref.: –
Time constant of integrator feedback Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 setpoint/actual value deviation (steady-state proportional ac-
tion).
S Applications:
Machining motions at position setpoint zero and dominant static friction can
be suppressed but result in a permanent distance-to-go, e.g. oscillation of
the positon controlled axis at zero speed (stick-slip effect) or overshooting in
µm-step method.
S Setting note:
Optimize this data starting at a high value until you find the best
compromise.
If the time constant integrator feedback
1 ms is set, feedback is disabled.

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4.3 Closed-loop velocity control

Integrator Velocity below which the integrator feedback becomes operative.

feedback
threshold
5422 FEEDBK_SPEED_THRESHOLD Cross ref.: –
Integrator feedback velocity threshold Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 10.0 0.0 120000.0 FLOAT Immediately

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 at
low velocity setpoints and stabilizes the axis at zero speed. At high velocities,
however, the effect of the I component is not restricted.

D component A derivative-action component (acceleration feedback) is implemented in the

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

5430 SPEEDCTRL_PT1_TIME [n] 0...7 index of the parameter set Cross ref.: –
Velocity controller smoothing time constant Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.25 0.25 100.0 FLOAT Immediately
5431 SPEEDCTRL_DIFF_TIME_A [n] 0...7 index of the parameter set Cross ref.: –
Velocity controller A derivative-action time (D component) Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.0 –100.0 100.0 FLOAT Immediately
5432 SPEEDCTRL_DIFF_TIME [n] 0...7 index of the parameter set Cross ref.: –
Velocity controller derivative-action time (D component) Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.0 –100.0 100.0 FLOAT Immediately
5433 SPEEDCTRL_DIFF_TIME_B [n] 0...7 index of the parameter set Cross ref.: –
Velocity controller B derivative-action time (D component) Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.0 –100.0 100.0 FLOAT Immediately

Similar to the P component setting, it is possible to set a D component at the A

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

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4.3 Closed-loop velocity control

Reference model

5414 SPEEDCTRL_REF_MODEL_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Natural frequency of reference model Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 150.0 0.0 1000.0 FLOAT Immediately
5415 SPEEDCTRL_REF_MODEL_DAMPING [n] 0...7 index of the parameter set Cross ref.: –
Reference model damping Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 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 parameterized by settings for natural frequency
(MD5414) and damping (MD 5415).
Controller optimization reference model:
Precondition: I-component=0 (MD 5409=0)
Objective: Overshooting in response to setpoint changes caused by the I
component can be reduced by means of the reference model.
Procedure:
1. Set I-action gain (MD 5406: SPEEDCTRL_GAIN_A)
(MD 5407: SPEEDCTRL_GAIN)
(MD 5408: SPEEDCTRL_GAIN_B)
to zero (make note of original values!).
2. Record frequency response of the closed (adjusted and optimized) velocity
control loop.
3. Adjust the frequency response of the reference model by matching the filter
natural frequency (MD 5414) and filter damping (MD 5415) to the frequency
response recorded in point 2..
In the ideal case of exact simulation, there is no deviation after the setpoint/
actual value comparison on the integrator.
4. Enter I-action gain as calculated in the preceding optimization step.

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02.99 4 Firmware Drive Functions
4.3 Closed-loop velocity control

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 ref.: –
Number of control output filters for velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 2 UNS.WORD Immediately

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

0 No control output filter active

1 Filter 1 active
2 Filters 1 and 2 active

Input of configuration of 2 control output filters. A selection of band-stops and

low passes is available. The parameters that can be set for each filter type must
be entered in the relevant machine data.

Note
Before the filter type is configured, the corresponding filter machine data must
be parameterized.

5201 OUTPUT_VCTRL_FILTER_CONFIG [n] 0...7 index of the parameter set Cross ref.: –
Control output filter type in velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 3 UNS.WORD Immediately

Table 4-2 Control output filter type in velocity controller

0 Low pass (see MD 5202/5203)

1st filter Bit 0
1 Band-stop (see MD 5210/5211/5212)
0 Low pass (see MD 5204/5205)
2nd filter Bit 1
1 Band-stop (see MD 5213/5214/5215)

Table 4-3 Filter combinations

Filter 2 Filter 1 MD 5201: OUTPUT_VCTRL_FILTER_CONFIG

PT2 PT2=0 0
PT2 BS=1 1
BS PT2 2
BS BS 3

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4.3 Closed-loop velocity control

5202 OUTPUT_VCTRL_FIL_1_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Natural frequency of control output filter 1 in velocity Relevant for: Protection level:
controller HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 1000.0 10.0 8000.0 FLOAT Immediately
5204 OUTPUT_VCTRL_FIL_2_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Natural frequency of control output filter 2 in velocity control- Relevant for: Protection level:
ler HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 1000.0 10.0 8000.0 FLOAT Immediately

The filter key data are defined in MD 5202, MD 5205 and MD 5210 to MD 5215.
Input of natural frequency for control output filters 1...2 (PT2 low-pass) in 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 ref.: –
Damping of control output filter 1 in velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 1.0 0.05 1.0 FLOAT Immediately
5205 OUTPUT_VCTRL_FIL_2_DAMP [n] 0...7 index of the parameter set Cross ref.: –
Damping of control output filter 2 in velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 1.0 0.05 1.0 FLOAT Immediately

Input of damping for control output filters 1...2 (PT2 low-pass) in the velocity
controller. The filters are activated in machine data MD 5200: NUM_OUT-
PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

5210 OUTPUT_VCTRL_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Blocking frequency of control output filter 1 in velocity Relevant for: Protection level:
controller HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 ref.: –
Blocking frequency of control output filter 2 in velocity con- Relevant for: Protection level:
troller HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 3500.0 1.0 7999.0 FLOAT Immediately

Input of blocking frequency for control output filters 1...2 (bandstop) in the veloc-
ity controller. The filters are activated in machine data MD 5200: NUM_OUT-
PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

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4.3 Closed-loop velocity control

5211 OUTPUT_VCTRL_FIL_1_BW [n] 0...7 index of the parameter set Cross ref.: –
Bandwidth of control output filter 1 in velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 500.0 5.0 7999.0 FLOAT Immediately
5214 OUTPUT_VCTRL_FIL_2_BW [n] 0...7 index of the parameter set Cross ref.: –
Bandwidth of control output filter 2 in velocity controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 500.0 5.0 7999.0 FLOAT Immediately

Input of –3dB bandwidth for control output filters 1...2 (bandstop) in the velocity
controller.
The filters are activated in machine data MD 5200: NUM_OUT-
PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

5212 OUTPUT_VCTRL_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –
Numerator bandwidth of control output filter 1 in velocity Relevant for: Protection level:
controller HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 ref.: –
Numerator bandwidth of control output filter 2 in velocity Relevant for: Protection level:
controller HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 0.0 0.0 7999.0 FLOAT Immediately

Input of numerator bandwidth for control output filters 1...2 (damped bandstop)
in the velocity controller. Setting a value of 0 initializes the filter as an undamped
band-stop.
The filters are activated in machine data MD 5200: NUM_OUT-
PUT_VCTRL_FILTERS and MD 5201: OUTPUT_VCTRL_FILTER_CONFIG.

4.3.3 Dynamic Stiffness Control (DSC)

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).

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4.4 Closed-loop force control

4.4 Closed-loop force control

Preconditions
S Pressure sensors must be installed
S Force limitation and/or static friction injection activated
(MD 5241: FORCECTRL_CONFIG)

S Piston position must have been calibrated (see Section 3.9.4)

The letters have the fol- AA AB Cylinders

lowing meaning:
A: Area FB
P: Pressure FA
F: Force
A B

PA PB

Measured
value sensing

AA AB
MD 5131 MD 5131
MD 5132 MD 5133
FA FB
–
DF=Fpiston=Factual
–
Fset

Force controller

Fig. 4-11 Actual force measurement sensing

Start-up of force To start up the force controller, it is possible to redirect the measuring functions
controller and function generator from the velocity controller to the force controller by set-
ting bit 8 in MD 5650. In this setting, velocity setpoints are interpreted as force
setpoints in units of kN. This mode is deactivated by resetting MD 5650, bit 8
(mm/min → kN).

Force limitation Force limitation is required

S in certain machining processes for which the “Travel to fixed stop” function
must be implemented or

S to work material in the machining of force profiles.

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).

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02.99 4 Firmware Drive Functions
4.4 Closed-loop force control

Force controller Input of configuration for force controller:

configuration

5241 FORCECTRL_CONFIG [n] 0...7 index of the parameter set Cross ref.: –
Configuration of force controller Relevant for: 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
Bit2= 0: Force limitation 2 off
Bit2= 1: Force limitation 2 on
Unit: Default: Minimum: Maximum: Data type: Effective:
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 as a function of load.
S Static friction injection (MD 5241 bit 1=1), see Section 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 force level falls below the specified limit, the velocity controller be-
comes active again, even with FFA. This can cause faults with FFA. At
higher velocities, this can also cause continuous alternation between the
force and velocity controller. This mode is therefore only suitable for low ve-
locities (<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 3710 or value from FXST[x]). Reference value (100%
value) of force limit for NC is MD 5725.
Force limitation remains active until the function FFA is deactivated, even if
the force has already fallen below the current force limitation.

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4.4 Closed-loop force control

FFA

t
0

F
Fact
Flimit

t
0
Mode
Fcontr. on

t
0

Fig. 4-12 Force limitation 2

Deselection of closed-loop force control by deactivating function “Travel to fixed

stop” bit.

4.4.1 Force limitation

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 ref.: –
Force limitation tolerance band about weight Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
N 10000.0 0.0 100000000.0 FLOAT Immediately
5231 FORCE_LIMIT_WEIGHT [n] 0...7 index of the parameter set Cross ref.: –
Weight force limitation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 in-
put by the NC, e.g. on travel to fixed stop. The lower of the two force limitation
values is then applied.

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02.99 4 Firmware Drive Functions
4.4 Closed-loop force control

4.4.2 Static friction injection

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 must 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 standstill and thus static friction is detected.

5232 STICTION_SPEED_THRESHOLD Cross ref.: –

Velocity threshold for static friction Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 10.0 0.0 500.0 FLOAT Immediately

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.
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.

Cutoff limit

5233 STICTION_COMP_THRESHOLD Cross ref.: –

Cutoff limit static friction Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 40.0 3.0 100.0 FLOAT Immediately

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.

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4.4 Closed-loop force control

Cylinder friction The cylinder friction force at a positive velocity can be set in MD 5234.
force

5234 STICTION_FORCE_POS Cross ref.: –

Friction force at velocity >0 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
N 100.0 –100000000.0 100000000.0 FLOAT Immediately

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.

5235 STICTION_FORCE_NEG Cross ref.: –

Friction force at velocity <0 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
N –100.0 –100000000.0 100000000.0 FLOAT Immediately

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.

4.4.3 Force controller

Feedforward Factor for setting the feedforward control gain in the force controller.
control gain of
force controller
5247 FORCE_FFW_WEIGHT Cross ref.: –
Feedforward control factor for force controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 0.0 120.0 FLOAT Immediately

Operative only if force limitation or static friction injection is activated

in MD 5241.
The more accurate the feedforward control setting, the more effective the force
limitation at high velocities.
An excessively high setting can result in continuous switching between force
and velocity controllers.
The area adaptation (MD 5462 and MD 5463) and controlled system gain (MD
5435) are taken into account by the feedforward control.

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4.4 Closed-loop force control

Controlled system
gain of force
controller
5240 FORCECONTROLLED_SYSTEM_GAIN Cross ref.: –
Controlled system gain of force controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
N/V 0.0 0.0 1000000000.0 FLOAT Immediately

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
rated volumetric flow of the servo solenoid valve. The value should not gener-
ally be altered.
The value in MD 5240 is the reference for the P gain of the force controller.
MD 5240 makes allowance for the effects of geometric dimensions.
The effect of the valve dynamic response is taken into account in MD 5242,
which means that the same gain value can always be set for an identical valve
dynamic response on different cylinders.

P component
of force controller

5242 FORCECTRL_GAIN [n] 0...7 index of the parameter set Cross ref.: –
P gain of force controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0.0 0.0 10000.0 FLOAT Immediately

If force limitation and/or static friction injection is activated in MD 5241, the P

gain of the force controller is entered in this machine data.
The P-gain reference is MD 5240 containing a value representing the overall
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.

5243 FORCECTRL_GAIN_RED Cross ref.: –

Reduction of force controller P component Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 40.0 0.1 100.0 FLOAT Immediately

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4.4 Closed-loop force control

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 to what value 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 ref.: –
Reset time of force controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
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 ref.: –
Force controller smoothing time constant Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.5 0.25 100.0 FLOAT Immediately
5246 FORCECTRL_DIFF_TIME [n] 0...7 index of the parameter set Cross ref.: –
D-action time of force controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.0 –10000.0 10000.0 FLOAT Immediately

If force limitation and/or static friction injection is activated in MD 5241, a

smoothing time constant of the force controller for derivative action is set in MD
5245 and, in addition to the force controller P component (MD 5242), a D-action
component (jerk feedback) in MD 5246.
If the D-action component of the force controller is deactivated (MD 5246), then
the smoothing function (MD 5245) is also rendered inoperative.
The D-action time setting (MD 5246) can be negative or positive. No D compo-
nent is active if the D-action time is set to zero.

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02.99 4 Firmware Drive Functions
4.4 Closed-loop force control

Feedforward con-
trol filter for force
controller
5260 NUM_FFW_FCTRL_FILTERS [n] 0...7 index of the parameter set Cross ref.: –
No. of force controller feedforward control filters Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 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

0 No feedforward control filter active (default)

1 Filter(s) activated

Note
Before the filter type is configured, the corresponding filter machine data must
be parameterized.

5261 FFW_FCTRL_FILTER_TYPE [n] 0...7 index of the parameter set Cross ref.: –
Type of feedforward control filter in force controller Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 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

0 Low pass (see MD 5264/5265)

Bit 0
1 Band-stop (see MD 5268/5269/5270)

5264 FFW_FCTRL_FIL_1_FREQ [n] 0...7 index of the parameter set Cross ref.: –
PT2 natur. freq. feedforward control filter1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 2000.0 10.0 8000.0 FLOAT Immediately

The filter key data are defined in MD 5264, MD 5265 and MD 5268 to MD 5270.

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4.4 Closed-loop force control

5265 FFW_FCTRL_FIL_1_DAMP [n] 0...7 index of the parameter set Cross ref.: –
PT2 damping for feedforward control filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0.7 0.2 1.0 FLOAT Immediately

Input of damping for feedforward control filter 1 (PT2 low-pass) in force control-
ler.

5268 FFW_FCTRL_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Blocking frequency of feedforward control filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 3500.0 10.0 7999.0 FLOAT Immediately

Input of 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 ref.: –
Bandwidth of feedforward control filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 500.0 5.0 7999.0 FLOAT Immediately

Input of –3 dB bandwidth for feedforward control filter 1 (band-stop) in force con-

troller.

5270 FFW_FCTRL_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –
Numerator bandwidth feedforward control filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 0.0 0.0 7999.0 FLOAT Immediately

Input of numerator bandwidth for feedforward control filter 1 (damped band-

stop) in force controller.
Setting a value of 0 initializes the filter as an undamped band-stop. The value
set in MD 5270 must not exceed twice the value set in MD 5269.

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4.5 Output of manipulated variables

4.5 Output of manipulated variables

4.5.1 Characteristics compensation

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 Cross ref.: –

Piston surface adaptation factor, positive Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 50.0 200.0 FLOAT Immediately
5463 AREA_FACTOR_NEG_OUTPUT Cross ref.: –
Piston surface adaptation factor, negative Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 50.0 200.0 FLOAT Immediately

In order to compensate the direction-dependent controlled-system gain on dif-

ferential cylinders, a characteristic with a gradient that is variable as a function
of direction has been implemented. Fig. 4-13 shows an example of this charac-
teristic and the mode of action of the associated machine data. In practice, only
one of the two gradients is weighted with a factor other than 100%. Normally, it
is the gradient that causes the cylinder piston to travel out that is weighted with
a factor of less than 100% (see also Section 2.3.1 and Appendix A).

Output
100%
MD 5462

–100%
Input
0 100%

–100%

– MD 5463

–200%

Fig. 4-13 Example of piston surface adaptation characteristic

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4.5 Output of manipulated variables

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 imple-
mented according to a root characteristic in such a way that the intersection
points lie on a continuous tangent; the rounding range can be parameterized.
Fig. 4-14 shows an example of this characteristic and the mode of action of the
associated machine data.
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. 4-14 Valve characteristic with breakpoint in zero, fine control and saturation ranges

S Valve characteristic with breakpoint in zero range

5480 POS_DUAL_GAIN_COMP_Z_FLOW Cross ref.: –

Knee-point compensation pos. flow in zero range Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.01 0.01 95.0 FLOAT Immediately
5481 POS_DUAL_GAIN_COMP_Z_VOLT Cross ref.: –
Knee-point compensation pos. voltage in zero range Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 0.0 95.0 FLOAT Immediately

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02.99 4 Firmware Drive Functions
4.5 Output of manipulated variables

5482 DUAL_GAIN_COMP_SMOOTH_Z_R Cross ref.: –

Knee-point compensation rounding in zero range Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 0.0 10.0 FLOAT Immediately
5483 NEG_DUAL_GAIN_COMP_Z_FLOW Cross ref.: –
Knee-point compensation neg. flow in zero range Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.01 0.01 95.0 FLOAT Immediately
5484 NEG_DUAL_GAIN_COMP_Z_VOLT Cross ref.: –
Knee-point compensation neg. voltage in zero range Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0.0 0.0 95.0 FLOAT Immediately

To calculate the inverse characteristic, a knee-point is defined in the positive

zero range of the valve characteristic with MD 5480 and MD 5481 and in the
negative zero range with MD 5483 and MD 5484.
The positive and negative valve flows at the knee-point referred to rated flow
(MD 5107) are entered in 5480 and MD 5483 respectively.
The valve voltage at the knee-point referred to the rated valve voltage (MD
5109) is entered in MD 5481.
When MD 5481 is set to default zero, there is no breakpoint in the positive
zero range.
When MD 5484 is set to default zero, there is not breakpoint in the negative
zero range.
The rounding range is parameterized in MD 5482.

S Valve characteristic with breakpoint in fine control range

5464 POS_DUAL_GAIN_COMP_FLOW Cross ref.: –

Knee-point compensation pos. flow Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 10.0 0.2 95.0 FLOAT Immediately
5465 POS_DUAL_GAIN_COMP_VOLTAGE Cross ref.: –
Knee-point compensation pos. voltage Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 10.0 0.2 95.0 FLOAT Immediately
5466 DUAL_GAIN_COMP_SMOOTH_RANGE Cross ref.: –
Rounding range for knee-point compensation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 2.5 0.0 10.0 FLOAT Immediately

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4.5 Output of manipulated variables

5467 NEG_DUAL_GAIN_COMP_FLOW Cross ref.: –

Knee-point compensation neg. flow Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 10.0 0.2 95.0 FLOAT Immediately
5468 NEG_DUAL_GAIN_COMP_VOLTAGE Cross ref.: –
Knee-point compensation neg. voltage Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 10.0 0.2 95.0 FLOAT Immediately

To calculate the inverse characteristic, the knee-point in the positive quad-

rant of the valve characteristic is defined in MD 5464 and MD 5465 and in
the negative quadrant with MD 5467 and MD 5468.
The positive and negative valve flows at the knee-point referred to rated flow
(MD 5107) are entered in 5464 and MD 5467 respectively.
The positive and negative valve voltages at the knee-point referred to rated
valve voltage (MD 5109) are entered in MD 5465 and MD 5468 respectively.
When the same values (defaults) are set in MD 5464 and MD 5465, the
characteristic is linear (without breakpoint in the zero range (default and
without saturation (default)).
These breakpoint data are preset from the valve data (MD 5110, MD 5111)
during the “Calculate controller data” operation. The presettings can be al-
tered later. The rounding range is not a valve data and is therefore only pre-
set to a default value. It can however be changed later by the user (MD
5466). If necessary, a measurement can be taken to obtain a precise set-
ting.

Note
A constant machining velocity of the drive directly at the knee-point of the valve
is not recommended.

S Valve characteristic with breakpoint at beginning of a saturation region

5485 POS_DUAL_GAIN_COMP_S_FLOW Cross ref.: –

Knee-point compensation pos. flow saturation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 0.2 100.0 FLOAT Immediately
5486 POS_DUAL_GAIN_COMP_S_VOLT Cross ref.: –
Knee-point compensation pos. voltage saturation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 0.2 100.0 FLOAT Immediately

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4.5 Output of manipulated variables

5487 NEG_DUAL_GAIN_COMP_S_FLOW Cross ref.: –

Knee-point compensation neg. flow saturation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 0.2 100.0 FLOAT Immediately
5488 NEG_DUAL_GAIN_COMP_S_VOLT Cross ref.: –
Knee-point compensation neg. voltage saturation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 100.0 0.2 100.0 FLOAT Immediately

To calculate the inverse characteristic, the beginning of a saturation range with

parabolic rounding in the positive quadrant of the valve characteristic is defined
in MD 5485 and MD 5486 and in the negative quadrant with MD 5487 and MD
5488.
The positive and negative valve flows at the beginning of the saturation region
referred to rated flow (MD 5107) are entered in MD 5485 and MD 5487 respec-
tively.
The positive and negative valve voltages referred to valve rated voltage (MD
5109) are entered in MD 5486 and MD 5488 respectively.
The saturation region is compensated by a root characteristic such that the in-
tersection point lies on a continuous tangent and the characteristic ends at the
point (100%, 100%).
With default 100% set in MD 5485 and MD 5486 or in MD 5487 and
MD 5488, there is no saturation region in the positive or negative quadrant.
For more detailed explanation, see also Section 2.3.1 and Appendix A.

Offset

5470 OFFSET_COMPENSATION Cross ref.: –

Offset compensation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 –4000 4000 WORD Immediately

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 initiated with MD 5650 (see Section
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 de-
activated with closed-loop force control.

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4.5 Output of manipulated variables

4.5.2 Control output filter

5280 NUM_OUTPUT_FILTERS [n] 0...7 index of the parameter set Cross ref.: –
Number of control output filters Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 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

0 No filter(s) active (default)

1 Filter(s) activated

Note
Before the filter type is configured, the corresponding filter machine data must
be parameterized.

5281 OUTPUT_FILTER_TYPE [n] 0...7 index of the parameter set Cross ref.: –
Type of control output filter Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 1 UNS.WORD Immediately

The type of control output filter is entered in this machine data.

Table 4-7 Type of control output filter

0 Low pass (see MD 5284/5285)

Bit 0
1 Band-stop (see MD 5288/5289/5290)

5284 OUTPUT_FIL_1_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Natural frequency of control output filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 1000.0 10.0 8000.0 FLOAT Immediately

The filter key data are defined in MD 5284, MD 5285 and MD 5288 to MD 5290.
Input of 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.

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4.5 Output of manipulated variables

5285 OUTPUT_FIL_1_DAMP [n] 0...7 index of the parameter set Cross ref.: –
Damping of control output filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 1.0 0.05 1.0 FLOAT Immediately

Input of damping for control output filter 1 (PT2 low-pass).

5288 OUTPUT_FIL_1_SUP_FREQ [n] 0...7 index of the parameter set Cross ref.: –
Blocking frequency of control output filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 3500.0 1.0 7999.0 FLOAT Immediately

Input of blocking frequency for control output filter 1 (bandstop)

5289 OUTPUT_FIL_1_BW [n] 0...7 index of the parameter set Cross ref.: –
Bandwidth of control output filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 500.0 5.0 7999.0 FLOAT Immediately

Input of –3dB bandwidth for control output filter 1 (bandstop).

5290 OUTPUT_FIL_1_BW_NUM [n] 0...7 index of the parameter set Cross ref.: –
Numerator bandwidth for control output filter 1 Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 0.0 0.0 7999.0 FLOAT Immediately

Input of numerator bandwidth for control output filter 1 (damped bandstop).

Setting a value of 0 initializes the filter as an undamped band-stop. The value
set in MD 5290 must not exceed twice the value set in MD 5289.

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4.5 Output of manipulated variables

4.5.3 Manipulated voltage limitation

5475 OUTPUT_VOLTAGE_LIMIT Cross ref.: –

Manipulated voltage limitation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
V 10.0 1.0 10.0 FLOAT Immediately
The manipulated variable setpoint is limited in the positive and negative direc-
tions to the value set in MD 5475 before the D/A conversion. An identical value
is set for both limits. A ZK3 message (can be interrogated via PLC) is activated
when the limitation is violated.
Manipulated
variable inversion
5476 OUTPUT_VOLTAGE_INVERSION Cross ref.: –
Manipulated variable inversion Relevant for: Protection level:
Bit 0= 0: No inversion HLA 3/3
1: Inversion
Unit: Default: Minimum: Maximum: Data type: Effective:
– 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 Section 3.9.1.

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4.6 Supply unit data

4.6 Supply unit data

The supply unit is defined by

S the modulus of elasticity of the hydraulic fluid,

S the system pressure and
S on pilot-actuated valves by the pilot pressure

S at the cylinder working temperature.

These data influence the limit data (maximum velocity, maximum force...) as
well as the dynamic response characteristics of the drive system (corner fre-
quencies).

5100 FLUID_ELASTIC_MODULUS Cross ref.: –

Fluid elastic module hydraulic oil Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 11000 1000 21000 FLOAT Immediately
5101 WORKING_PRESSURE Cross ref.: –
System pressure Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 0.0 0.0 350.0 FLOAT Power On
5102 PILOT_OPERATION_PRESSURE Cross ref.: –
Pilot pressure Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 0.0 0.0 250.0 FLOAT Immediately

Note
The variable of the elasticity of oil as a function of temperature can be ignored
with respect to industrial hydraulics.

MD 5100 defines the compressibility of the hydraulic fluid.

MD 5101 defines the pressure supplied by the hydraulic power unit.
MD 5102 defines the pressure for a pilot-actuated valve. Zero must be entered
valves without pilot actuation.

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02.99
4.7 Valve

4.7 Valve
Valve data The rated valve data define the key valve data at the rated operating point. The
latter is defined by the
S rated flow,
S rated pressure drop and
S rated voltage.

5106 VALVE_CODE Cross ref.: –

Valve code number Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 2000 UNS.WORD Immediately
5107 VALVE_NOMINAL_FLOW Cross ref.: –
Rate valve flow Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
l/min 0.0 0.0 1000 FLOAT Immediately
5108 VALVE_NOMINAL_PRESSURE Cross ref.: –
Rated valve pressure drop (per control edge) Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 35.0 1.0 200.0 FLOAT Immediately
5109 VALVE_NOMINAL_VOLTAGE Cross ref.: –
Rated valve voltage Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
V 10.0 0.5 15.0 FLOAT Immediately

Valves with the associated data are included in the valve selection list (see Sec-
tion 2.3.2).
Other valve data are as follows:
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.

5110 VALVE_DUAL_GAIN_FLOW Cross ref.: –

Valve knee-point flow rate Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 10.0 0.2 95.0 FLOAT Immediately
5111 VALVE_DUAL_GAIN_VOLTAGE Cross ref.: –
Valve knee-point voltage Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 10.0 0.2 95.0 FLOAT Immediately

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4.7 Valve

A valve characteristic as shown in Fig. 2-10 results in an entry of 10 % in

MD 5110 and 40 % in MD 5111. Entering the same value in both machine data
produces a linear characteristic (default setting).

5112 VALVE_FLOW_FACTOR_A_B Cross ref.: –

Valve flow ratio betw. A and B ends Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 1.0 0.5 2.0 FLOAT Immediately

The flow ratio specifies the ratio between the rated flow towards the A end and
the rated flow towards the B end.

5114 VALVE_NATURAL_FREQUENCY Cross ref.: –

Valve natural frequency Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 150.0 1.0 1000.0 FLOAT Immediately
5115 VALVE_DAMPING Cross ref.: –
Valve damping Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0.8 0.4 1.0 FLOAT Immediately

To dimension the velocity controller, the transmission behavior of the valve on

conversion of the voltage setpoint to spool position is approximated as a PT2
low-pass.
The valve natural frequency can be read off at a phase shift of –180°. The natu-
ral valve frequency with a valve modulation of 10 % in relation to 100 bar pilot
pressure is stated in MD 5114.
The valve damping can be calculated from the amplitude overshoot at resonant
frequency for values of less than 0.7. The valve damping for a valve modulation
of 20 % in relation to 100 bar pilot pressure is stated in MD 5115.

Special features To allow special valve features to be taken into account, machine data MD 5113
with control bits has been introduced.

5113 VALVE_CONFIGURATION Cross ref.:–

Valve configuration Relevant for: Protection level:
Bit 0= 0: Directly actuated valve HLA 3/3
1: Pilot-actuated valve
Bit 2/Bit 1= 00: No fail-safe
01: Fail safe closed
10: Fail-safe open
11: –
Bit 3= 0: No differential circuit
1: Differential circuit
Bit4= 0: 7-pin connector
1: 12-pin connector
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 1F UNS.WORD Immediately

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4.8 Cylinder drive

4.8 Cylinder drive

Cylinder data

5131 CYLINDER_PISTON_DIAMETER Cross ref.: –

Cylinder piston diameter Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 500.0 FLOAT Power On
5132 CYLINDER_ROD_A_DIAMETER Cross ref.: –
Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 500.0 FLOAT Power On
5133 CYLINDER_ROD_B_DIAMETER Cross ref.: –
Cylinder piston rod diameter at B end Relevant for: Protection level:
HLA
Immediately
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 500.0 FLOAT Power On
5134 PISTON_STROKE Cross ref.: –
Piston stroke Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 3000.0 FLOAT Immediately
5135 CYLINDER_DEAD_VOLUME_A Cross ref.: –
Cylinder dead volume at A end Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ccm 0.0 0.0 200000.0 FLOAT Immediately
5136 CYLINDER_DEAD_VOLUME_B Cross ref.: –
Cylinder dead volume at B end Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ccm 0.0 0.0 200000.0 FLOAT Immediately

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 Section 2.3.1 and
Appendix A.

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02.99 4 Firmware Drive Functions
4.9 Drive data

4.9 Drive data

Valve-to-drive
connection

5140 VALVE_CYLINDER_CONNECTION Cross ref.: –

Valve-cylinder connection configuration Relevant for: Protection level:
Bit 0 = 0: Valve A on cylinder A HLA 3/3
1: Valve A on cylinder B
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 1 UNS.WORD Immediately
5141 PIPE_LENGTH_A Cross ref.: –
Pipe length at A end Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 10000.0 FLOAT Immediately
5142 PIPE_LENGTH_B Cross ref.: –
Pipe length at B end Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 10000.0 FLOAT Immediately
5143 PIPE_INNER_ DIAMETER_A_B Cross ref.: –
Internal pipe diameters at A and B Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 5.0 0.0 100.0 FLOAT Immediately

These machine data provide information about the valve-to-drive connection.

They are used to preset other machine data during the “Calculate drive model
data” and “Calculate controller data” routines. If there is a pipe between the
valve and cylinder, then the dead volume of the pipe can be calculated from the
pipe length (A and B ends) and the inner pipe diameter. If the valve is mounted
directly on the cylinder, then zero must be entered for the pipe length at each
end. The dead volume affects the natural frequency of the drive.
For more detailed explanation of the drive data, see also Section 2.3.4 and Ap-
pendix A.

Mechanical drive
components

5150 DRIVE_MASS Cross ref.: –

Moved drive mass Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
kg 0.0 0.0 20000.0 FLOAT Immediately

The movement of the piston rod is transmitted to other mechanical components

(e.g. table, tools, ...). The total moved mass must be specified as a machine
data (MD 5150).

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4.9 Drive data

Note
The mass of the drive is a critical parameter and should be calculated as ex-
actly as possible!

5151 CYLINDER_A_ORIENTATION Cross ref.: –

Cylinder mounting position referred to A end Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Degrees 0.0 –90.0 90.0 FLOAT Immediately
5152 CYLINDER_FASTENING Cross ref.: –
Stationary part of HLA Relevant for: Protection level:
Bit 0= 0: Cylinder HLA 3/3
1: Piston rod
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 1 UNS.WORD Immediately

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
MD 5151

Negative sign in
MD 5151

MD 5150

Fig. 4-15 Mounting position of drive referred to A end

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02.99 4 Firmware Drive Functions
4.9 Drive data

Dynamic drive
model data

5160 PISTON_POS_MIN_NAT_FREQ Cross ref.: –

Min. natural frequency, piston position Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 0.0 3000.0 FLOAT Immediately
5161 DRIVE_DAMPING Cross ref.: –
Drive damping Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0.1 0.01 1.0 FLOAT Immediately
5162 DRIVE_NATURAL_FREQUENCY_A Cross ref.: –
Natural frequency of drive A Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 1.0 1.0 2000.0 FLOAT Immediately
5163 DRIVE_NATURAL_FREQUENCY Cross ref.: –
Natural frequency of drive Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 1.0 1.0 2000.0 FLOAT Immediately
5164 DRIVE_NATURAL_FREQUENCY_B Cross ref.: –
Natural frequency of drive B Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Hz 1.0 1.0 2000.0 FLOAT Immediately
5180 CLOSED_LOOP_SYSTEM_DAMPING Cross ref.: –
Selected damping for closed-loop system Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0.7 0.2 1.0 FLOAT Immediately

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.
Machine data MD 5180: CLOSED_LOOP_SYSTEM_DAMPING can be set to
specify the degree of damping to be applied in calculating the control loop dur-
ing “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

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4.10 Position measuring system

4.10 Position measuring system

Description Only one measuring system can be connected for each axis to measure the
position of the piston rod. The A and B tracks of the measuring system must
produce sinusoidal signals offset by 90° and an amplitude of 1 Vpp. The scale
graduations of a linear scale are subdivided 2048 times in the HLA module, the
lower bits losing their significance in some cases. The sign of the actual-value
sensor can be reversed. (Signs are reversed by a software function).

Minimum and The minimum or maximum possible velocity is dependent upon the position
maximum measuring 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 Section 4.13.1).
Vmax must not exceed the 350 kHz bar frequency of the connected measur-
ing system.
Vmax,bar=scale graduation  350000 s–1

S Vmin: The number of crossed graduations per velocity controller cycle is

small at low velocities. In extreme cases, this can result in uneven move-
ments at low velocities, large scale graduation and short velocity controller
cycle.
Improve by: Select another position measuring system with smaller
scale graduations or increase the velocity controller cycle.

Phase error A phase error on tracks A and B can be corrected with the phase error com-
compensation pensation function.

5008 ENC_PHASE_ERROR_CORRECTION Cross ref.: –

Encoder phase error compensation Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Degrees 0.0 –20.0 20.0 FLOAT Immediately
5011 ACTUAL_VALUE_CONFIG Cross ref.: –
Actual-value sensing configuration Relevant for: Protection level:
Bit 0= 0: No inversion HLA 3/3
1: Inversion of actual value
Bit1= 0: No phase error compens. activated
1: Phase error compensation activated
Bit3= 0: No absolute value encoder (EnDat)
1: Absolute value encoder (EnDat) connected
Bit4= 0: No linear measuring system
1: Linear measuring system connected
Bit7= 0: No distance-coded measuring system
1: Distance-coded measuring system connected
Bit8= 0: No zero marker selection by NC
1: Zero marker selection by NC
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 65535 UNS.WORD Power On

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4.10 Position measuring system

Scale graduations
of linear scale

5024 DIVISION_LIN_SCALE Cross ref.: –

Linear scale graduations Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
nm 20000 1000 (0) 5000000 UNS.WORD Power On

The standard parameterizing machine data provided support only linear mea-
suring systems. ROD encoders must be converted by the user, i.e. the 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 encoders cannot be implemented until sofware version
HLA 01.01.11 and beyond

5021 ENC_ABS_TURNS_MOTOR Cross ref.: –

Multi-turn resolution of absolute encoder on motor Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
Rev 4096 0000 65535 WORD Power On

Number of displayable revolutions of absolute encoder in motor measuring sys-

tem. The value is read-only.

5022 ENC_ABS_RESOL_MOTOR Cross ref.: –

Measuring steps of absolute track in motor Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 8192 0000 65535 WORD Power On

Resolution of motor absolute encoder in measuring pulses per revolution. The

value is read-only.

5023 ENC_ABS_DIAGNOSIS_MOTOR Cross ref.: –

Diagnosis bits of absolute encoder, measuring system Relevant for: Protection level:
Bit 0=1: “Lighting failure” HLA 3/3
Bit 1=1: “Signal amplitude too low”
Bit 2=1: “Faulty code connection”
Bit 3=1: “Overvoltage”
Bit 4=1: “Undervoltage”
Bit 5=1: “Overcurrent”
Bit 6=1: “Battery must be replaced”
Bit 7=1: “Checksum error”
Bit 8=1: “EnDat encoder cannot be used”
Bit 9=1: Reserved
Bit 10=1: “Protocol cannot be interrupted”
Bit 11=1: “SSI level in data line detected”
Bit 12=1: “TIMEOUT on measured value reading”
Bit 13=1: “CRC error”
Bit 14=1: Unassigned
Bit 15=1: “Encoder defective”
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 BFFF UNS.WORD Immediately

Diagnostic bits of absolute encoder, motor measuring system

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4.10 Position measuring system

Actual position

5040 PISTON_ZERO Cross ref.: –

Piston zero in relation to machine zero Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 –1000000.0 100000.0 FLOAT Immediately

The offset between the piston zero (end stop at A end) and machine 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).

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4.11 Pressure sensors

4.11 Pressure sensors

Sensor adjustment

5550 PRESSURE_SENS_A_REF Cross ref.: –

Reference value of pressure sensor A at 10 V Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 200.0 50.0 400.0 FLOAT Immediately
5552 PRESSURE_SENS_B_REF Cross ref.: –
Reference value of pressure sensor B at 10 V Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 200.0 50.0 400.0 FLOAT Immediately

The pressure at which the pressure sensor at the A and B cylinder ends outputs
10 V is entered in bar in MD 5550: PRESSURE_SENS_A_REF and MD 5552:
PRESSURE_SENS_B_REF.
The pressure sensor should have a range of 0 to 10 V, with 0 bar pressure rep-
resented by 0 V and the reference value (MD 5550 or. MD 5552) by 10 V.

Offset adjustment

5551 PRESSURE_SENS_A_OFFS Cross ref.: –

Offset adjustment for pressure sensor A Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 –32760 32760 WORD Immediately
5553 PRESSURE_SENS_B_OFFS Cross ref.: –
Offset adjustment for pressure sensor B Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 –32760 32760 WORD Immediately

The offset of the pressure sensor at the cylinder A and B ends is adjusted in
ADC increments in MD 5551: PRESSURE_SENS_A_OFFS and MD 5553:
PRESSURE_SENS_B_OFFS.
The pressure indicator should also display 0 bar at zero pressure. If the
velocity controller cycle is altered, the offset must be adjusted again.

Note
For automatic offset adjustment, see Section 3.9.2.

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4.12 Terminals

4.12 Terminals

ON/OFF sequence Terminals are provided on connectors X431/X432 of the HLA module and X121
of the NE module for the purpose of implemented 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 Control word

controller enable Velocity
term. 64 setpoint
&
Controller enable NC braking ramp
Controller enable Preset Timer
error run
Timer down
power Status
disable & controller
MD 5530 enable
Bit 3=1 Status
Preset power en-
OR Preset Timer
Timer able
run
Timer run Timer manip-
External 26.5 V down &
available power enab- down ulated vari-
& ling period able time ON
Power enable
term. 63
Power enable &
Control word
term. 663 power enable
Power enable
NC
Power disable
error 24 V for shutoff
CLEAR
valve ON

Preset Timer SET

run
Timer down
manipulated 24 V servo so-
variable time lenoid valve
SET ON
OFF
&
MD 5530 & CLEAR
Bit 4=1 OR
MD 5530
Bit 0=1

Fig. 4-16 Enabling logic on HLA module

External 26.5 V The 24 V voltage for the shutoff valve and valve electronics is supplied from an
supply external source connected via the HLA module.

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This voltage source is monitored by the HLA module such that an internal sig-
nalling bit “24 V valve supply voltage missing” is set by the hardware when the
voltage drops below a specific threshold. As long as the “valve supply voltage
missing” bit is set, a power enable command is rejected and thus the status bit
“Velocity controller enable” also set 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
26.5 V 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
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
S the tolerances of the capacitors,
The available reaction time is mainly defined by
S the power required for the current machining step,
S the response time of the shutoff valves and
S the trip threshold of the servo solenoid valves.

5532 POWER_ENABLE_DELAY Cross ref.: –

Power enable delay period Relevant for: Protection level:
HLA
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 100 0 300 UNS.WORD Immediately

If a shutoff valve is connected (MD 5530, bit 0=1), the switch remains open
for that time, i.e. the shutoff valve is closed.
This gives the servo solenoid valve time to move into the mid-position with-
out pressure from the fail-safe position. In such cases, the power 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 shutoff valve is connected, zero can be entered as the power enabling
delay period.

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4.12 Terminals

Figs. 4-17 and 4-18 show the system response to 24 V ON and OFF for a con-
figuration with and without shutoff valve.

Chronological sequence after connection of 24 V with shutoff valve

Power enable and velocity controller commands issued, setpoint > 0

24 V supply

24 V missing
message
Switch for closed
servo solenoid
open
valve supply The valve supply is disconnected only
Valve spool if bit 4 in MD 5530 is set to zero
position Zero
Back-up capacitor prolongs 24 V
Fail-safe supply for valve electronics
Switch for Power enable delay time
closed
Shutoff valve open
Shutoff valve open
closed
Status bit
Power enable

Status bit Manipulated variable enable delay

Velocity
controller enable
Effective
velocity
setpoint

Fig. 4-17 Chronological sequence after connection of 24 V supply, with shutoff valve

Chronological sequence after connection of 24 V without shutoff valve

Power enable and velocity controller enable commands issued, setpoint > 0

24 V supply

24 V missing
message
Switch for servo
solenoid valve closed
open
supply
Valve spool
position Zero
Fail-safe
Switch for Power enable delay period MD 5532
closed
Shutoff valve
open
Shutoff valve open No shutoff valve connected
closed
Status bit
Power enable

Status bit Manipulated variable delay time MD 5531

Velocity
controller enable
Effective
velocity
setpoint

Fig. 4-18 Chronological sequence after connection of 24 V supply, without shutoff valve

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4.12 Terminals

Power enable The power enabling command (corresponding to pulse enable on an electrical
drive) can be issued and/or cancelled 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 ref.: –
Safety configuration Relevant for: Protection level:
Bit 0= 0: Without shutoff valve
HLA 3/3
1: With shutoff valve
Bit 1= 0: Central shutoff valve
1: Axis-specific shutoff valve
Bit 2= 0: No valve spool checkback
1: Valve spool checkback available
Bit 3= 0: Velocity controller disable with power disable (PD)
1: Velocity controller disable without power disable (PD)
Bit 4= 0: Servo solenoid valve supply switched off at PD with
switchoff valve (no meaning without switchoff valve)
1: Servo solenoid valve remains switched on at PD with
switchoff valve (no meaning without switchoff valve)
(PD Power disable)
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 4 0 31 UNS.WORD Immediately
5531 OUTPUT_ENABLE_DELAY Cross ref.: –
Manipulated variable enable delay Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 300 0 500 UNS.WORD Immediately

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 shutoff valve to open or, in sys-
tems without shutoff valve, to allow the valve spool to change from fail-safe to
zero position.
Switching of the shutoff vavle supply
If a shutoff valve is parameterized in MD 5530 (bit 0 or bit 1 = 1) and the supply
voltage of the servo solenoid valve is to be switched off when the power is dis-
abled (MD 5530 bit=0), the manipulated variable delay time (MD 5531) is the
time it takes until the voltage supply of the servo solenoid valve is interrupted.
The shutoff valve can be closed during this period.
Operating sequence for PE (power enable) (ext. 24 V supply available, con-
trollers enabled):
S 24 V supply for servo solenoid valve is switched on immediately (if it is not
already connected).
S If 24 V supply for servo solenoid valve was available, then 24 V supply for
shutoff 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 shutoff valve has been switched on, the status
word “Velocity controller enable” is not set until the manipulated variable
enable delay has run down.

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4.12 Terminals

Operating sequence for PD (power disable):

S 24 V supply for shutoff valve is disconnected immediately (shutoff valve

closes).

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 shutoff valve), then the 24 V supply for the
servo solenoid valve is switched off immediately (servo solenoid valve
moves to fail-safe position).

S “Velocity controller enable” status bit is reset immediately.

– Valve setpoint=0 V is output
– I-action components of controllers are cancelled.
– Valve spool monitoring is deactivated
S If a central shutoff valve is installed, it is the user’s responsibility to gate
the signals (e.g. using the PLC) in such a way that the central shutoff valve
is actuated when the power is disabled.
To prevent errors on other axes, it should be ensured that all axes whose
pressure is supplied via the central shutoff valve also receive the “power
disable” command when the central shutoff valve is actuated.
S If a separate shutoff valve (axis-specific shutoff valve) is installed for each
axis, this need only be connected to the “shutoff valve” relay output of the
relevant axis.
After the power has been disabled, the switch for the 24 V supply is either
opened or not (depending on the setting of bit 4 in MD 5530) at the end of the
manipulated variable enable delay. The default setting has been selected such
that the 24 V valve supply voltage is disconnected (bit 4 =0) so as to bring the
valve into the fail-safe position.
This will not be necessary if a shutoff valve is installed and actuated. This func-
tion has been integrated for cases where a shutoff valve is parameterized, but
not actually connected. In such cases, this function prevents the drive from be-
ing able to drift after a power disable. After a function test, bit 4 in MD 5530 can
be set to 1.

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.

S manipulated variable enable delay run down,

S 24 V supply for shutoff and SS valves ON,
S power enable signal set and
S no errors,
then the “Velocity controller enable” status bit is set.

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Mode of operation when “Velocity controller enable” bit is set:

S Valve setpoint is output by the velocity controller
S I-action component is enabled
S Valve spool monitor is activated
If a velocity controller disable is requested, a zero velocity setpoint is output.
S The braking time set in MD 5402 acts as a speed setpoint adjustment ramp
(acceleration limitation).
S The setting in MD 5402 corresponds to the time required by the braking
ramp to decelerate the cylinder from the speed in MD 5401 down to zero.
This ramp is effective only when the velocity controller is disabled since, in
this case, the acceleration limits programmed in the control are ignored.
Otherwise, the control system has the responsibility of limiting acceleration
rates.
S In cases where velocity controller disable followed by a power disable is
requested
(MD 5530 bit 3=0), then the delay set in MD 5404:
POWER_DISABLE_DELAY is left to run down after the velocity controller
disable request until the power disable signal is set. When MD 5530, bit 3=1,
MD 5404 has no meaning (drive continues to operate under closed-loop
control with a zero velocity setpoint after a velocity controller disable re-
quest).
Velocity controller
disable
5402 SPEED_CTRL_DISABLE_STOPTIME Cross ref.: –
Braking time for controller disable Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 0.0 0.0 120000.0 FLOAT Immediately
5404 POWER_DISABLE_DELAY Cross ref.: –
Power disable timer Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 100 0 100000 FLOAT Immediately

Setup mode If the setup mode terminal (term. 112 on NE module) is selected, the velocity
setpoint is limited to the value programmed in MD 5420.
Function switch
5012 FUNC_SWITCH Cross ref.: –
Status word (PLC readable) Drive ready Relevant for: Protection level:
Bit 2=0:Drive signaled as ready if not drive alarm is pending HLA 3/3
Bit 2=1:Drive signaled as ready if not drive alarm is pending
and terminals 63, 64, 48 and 663=1
Bit 4=1:ZK2 parameterization error
Bit 14=1:Valid offset between machine zero and actual value
zero
Bit 15=1:Valid offset between piston zero and machine zero
Unit: Default: Minimum: Maximum: Data type: Effective:
– 4 0 65535 UNS.WORD Immediately

Only bits 2 and 4 are relevant for the user.

SIMRDY This LED indicates the readiness to operate of the drive unit (Simodrive Ready
terminal 72/73 –> device bus; cannot be changed by MD 5012).

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4 Firmware Drive Functions 02.99
4.13 Mounting functions

4.13 Monitoring functions

4.13.1 Alarms
Power On alarms

5600 ALARM_MASK_POWER_ON Cross ref.: –

Concealable alarms (Power On) Relevant for: Protection level:
Bit 4: “Measuring circuit measuring system” HLA 3/3
Bit 5: Measuring circuit absolute track
Bit 8: “Zero marker error”
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately
5612 ALARM_REACTION_POWER_ON Cross ref.: –
Config. shutdown reaction to PO alarms Relevant for: Protection level:
Bit 0= 0: No enable signal cancellation in response to HLA 3/3
internal errors
1: Enable signal cancellation in response to internal
errors
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately
5731 CL1_PO_IMAGE Cross ref.: –
Image ZK1_PO register Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately

MD 5600: ALARM_MASK_POWER_ON can be set to conceal Power On

alarms. If the relevant bit is set to 0, the corresponding error monitoring function
is active. If the bit=1, the error monitoring function is suppressed. The default
setting is “active” for all monitoring functions.
MD 5612: ALARM_REACTION_POWER_ON is set to configure switchover of
the relevant Power On alarm.
For alarm messages, see Chapter 6, numbers 300500...300599.
RESET alarms

5601 ALARM_MASK_RESET Cross ref.: –

Concealable alarms (Reset) Relevant for: Protection level:
Bit 7: “Valve controller not reacting” HLA 3/3
Bit 8: “Velocity controller at limit”
Bit 9: “Encoder limit frequency exceeded”
Bit 10: “Piston position negative”
Bit 11: “Pressure measurement failure”
Bit 12: “Force limitation OFF”
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately
5613 ALARM_REACTION_RESET Cross ref.: –
Config. shutdown reaction to RESET alarms Relevant for: Protection level:
Bit 0= 0: No enable signal cancellation in response to HLA 3/3
configuration errors
1: Enable signal cancellation in response to
configuration errors
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately

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5732 CL1_RES_IMAGE Cross ref.: –

Image ZK1_RES register Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately

MD 5601: ALARM_MASK_RESET can be set to conceal Reset alarms. If the

relevant bit is set to 0, the corresponding error monitoring function is active. If
the bit=1, the relevant error message is suppressed. The default setting is “ac-
tive” for all monitoring functions.
MD 5613: ALARM_REACTION_RESET is set to configure switchover of the
relevant Reset alarm.
Alarm messages, see Chapter 6, numbers 300600...300699.

Measuring circuit
limit frequency
reached
5609 ENC_SPEED_LIMIT Cross ref.: –
Max. measuring speed of linear scale Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 240 000.0 1.0 240 000.0 FLOAT Immediately

The limit frequency of the measured-value conditioning hardware is monitored

with respect to A/B signals. The limit frequency is calculated from machine data
MD 5005 and MD 5609. It is approximately 100 kHz and is normally specified
by the measuring system manufacturer.
Maximum measuring velocity (MD 5609) / increments (MD 5005) = encoder limit
frequency
Example: 120 000 mm/min / 20 µm = 100 kHz

Velocity controller
at limit

5605 SPEEDCTRL_LIMIT_TIME Cross ref.: –

Time for velocity controller at limit Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 200.0 20.0 1000.0 FLOAT Immediately
5606 SPEEDCTRL_LIMIT_THRESHOLD Cross ref.: –
Threshold for velocity controller at limit Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 120 000.0 0.0 120 000.0 FLOAT Immediately

A message is activated if the manipulated voltage on the D/A converter is at the

limit continuously for a parameterizable time period and, at the same time, the
actual velocity is lower than a parameterizable threshold (MD 5606).

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4 Firmware Drive Functions 02.99
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Valve spool
is not responding

5614 VALVE_ERROR_TIME Cross ref.: –

Valve spool monitoring timer Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
ms 50 1 100 UNS.WORD Immediately

The valve spool position is returned on all Bosch valves. 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 checkback signal is configured for the valve spool position (MD 5530).

4.13.2 Variable signalling functions

Input bit field for controlling the variable signalling function.

5620 PROG_SIGNAL_FLAGS Cross ref.: –

Bits of variable signalling function Relevant for: Protection level:
Bit 0= 0: Variable signalling function; not active HLA 3/3
1: Variable signalling function; active
Bit1= 0: Segment of variable signalling function; address
space X
1: Segment of variable signalling function; address
space Y
Bit 2=0: Compar. var. sign. fct.; compare without sign
1: Compar. var. sign. fct.; compare with sign
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 7 UNS.WORD Immediately

Note
Bit 1 is effective only if signal number 0 is selected in MD 5621: PROG_SIG-
NAL_NR.

A random memory location from address space X or Y in the data RAM is moni-
tored for violation of a parameterizable threshold for the variable signalling func-
tion. A tolerance band can be set around this threshold; this is taken into ac-
count when the threshold is scanned for violation in either direction. Any
violation of the tolerance band is signalled to the PLC. This violation message
can be linked to a pickup and/or dropout delay. The signalling function operates
in a 4 ms cycle.

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4.13 Mounting functions

Threshold Tolerance band

Message to PLC
t

Pickup delay time Dropout delay time

Fig. 4-19 Variable signalling function

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.

The following machine data are related to MD 5620:

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
Changed values which are entered in the machine data MD 5621 to MD 5624
while the monitoring is already active ( MD 5620, Bit 0 = 1) do not automati-
cally have the result that the PLC message is reinitialized, that means reset 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.

5621 PROG_SIGNAL_NR Cross ref.: –

Signal number of variable signalling function Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 100 UNS. WORD Immediately

Input of signal number of memory location which must be monitored by the vari-
able signalling function.

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Table 4-8 Signal number of variable signalling function

Signal number Signal name Normalization

(LSB corresponds to:)
0 No signal –
1 No signal –
2 Pressure p(A) (with pressure sensing) MD 57101)
3 Pressure p(B) (with pressure sensing) MD 57101)
4 Actual value spool value MD 57091)
5 Valve spool setpoint MD 57091)
6 Actual velocity value MD 57111)
7 Velocity setpoint (before filter, limitation) MD 57111)
8 Velocity setpoint (after filter, limitation) MD 57111)
9 Velocity setpoint reference model MD 57111)
10 Actual force (with pressure sensing) MD 57131)
11 Active power 1 inc 0.01 kW
12 Control deviation of velocity controller MD 57111)
13 Velocity controller P component MD 57091)
14 Velocity controller I component MD 57091)
15 Velocity controller D component MD 57091)
16 Velocity controller feedforward control component MD 57091)
17 Friction feedforward control component velocity controller MD 57091)
18 Velocity controller output (before filter) MD 57091)
19 Velocity controller output (after filter) MD 57091)
20 Actual position MD 57141)
21 Force setpoint MD 57131)
22 Force controller control deviation MD 57131)
23 Force controller P component MD 57091)
24 Force controller I component MD 57091)
25 Force controller D component MD 57091)
26 Feedforward control component force controller MD 57091)
27 Force controller output MD 57091)
28 Zero marker signal –
29 BERO signal –

1) see Section 4.14.3

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5622 PROG_SIGNAL_ADDRESS Cross ref.:

Address to be monitored by variable signalling function Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately

Input of address of memory location which must be monitored by the variable

signalling function.

Note
This machine data is effective only if the signal number is set to 0 (refer to
MD 5621).

5623 PROG_SIGNAL_THRESHOLD Cross ref.: –

Threshold for variable signalling function Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately

Input of threshold for the memory location address entered in MD 5622:

PROG_SIGNAL_ADDRESS which is to be monitored by the variable signalling
function. In combination with MD 5624: PROG_SIGNAL_HYSTERESIS this
data defines the actual value to be checked by the monitoring function (see dia-
gram under MD 5620, Fig. 4-19).

Note
Depending on how machine data MD 5620: PROG_SIGNAL_FLAGS is set, the
numeric setting in MD 5623 is interpreted as an unsigned value (bit 2 = 0) or a
signed value (bit 2 = 1).

5624 PROG_SIGNAL_HYSTERESIS Cross ref.: –

Hysteresis for variable signalling function Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately

Input of hysteresis (tolerance band) for the memory location address entered in
MD 5622: PROG_SIGNAL_ADDRESS which is to be monitored by the variable
signalling function. In combination with MD 5623: PROG_SIGNAL_THRESH-
OLD, this data defines the actual value to be checked by the monitoring function
(see diagram under MD 5620, Fig. 4-19).

Note
Depending on how machine data MD 5620:
PROG_SIGNAL_FLAGS is set, the numeric setting in MD 5623 is interpreted
as an unsigned value (bit 2 = 0) or a signed value (bit 2 = 1).

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5625 PROG_SIGNAL_ON_DELAY Cross ref.: –

Pickup delay for variable signalling function Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 10 000 UNS.WORD Immediately

Input of pickup delay for setting of message if the monitored quantity exceeds
the threshold setting (with hysteresis) (see diagram under MD 5620, Fig. 4-19).

Note
Changing the settings in MD 5625: PROG_SIGNAL_ON_DELAY and
MD 5626: PROG_SIGNAL_OFF_DELAY affects a time watchdog that is al-
ready running. The monitor is initialized with the new time settings.

5626 PROG_SIGNAL_OFF_DELAY Cross ref.: –

Dropout delay for variable signalling function Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 10 000 UNS.WORD Immediately

Input of dropout delay for resetting of message if the monitored quantity drops
below the threshold setting (with hysteresis) (see diagram under MD 5620, Fig.
4-19).

Note
Changing the settings in MD 5625: PROG_SIGNAL_ON_DELAY and
MD 5626: PROG_SIGNAL_OFF_DELAY affects a time watchdog that is al-
ready running. The monitor is initialized with the new time settings.

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4.14 Service functions

4.14 Service functions

For explanations regarding the
S Measuring functions
– Measurement of valve control loop
– Measurement of velocity control loop
– Measurement of position control loop
S function generator,
S Circularity test
S Servo trace
S DAC configuration
please refer to Section 3.11, Start-Up Functions.

5650 DIAGNOSIS_CONTROL_FLAGS Cross ref.: –

Diagnostic control Relevant for: Protection level:
Bit 0: Min/Max memory HLA 3/3
Bit 1: Min/Max memory segment
Bit 2: Signed comparison
Bit 8: Interpretation of velocities as forces
measuring functions, function generator
Bit 12: Offset adjustment P_a, P_b
Bit 13: Offset adjustment of valve spool setpoint
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately

MD 5650 is important for diagnostic and start-up purposes.

For information about adjusting the pressure sensor and valve setpoint offsets,
see Section 3.9.2.
To start up the force controller, it is possible to redirect the measuring functions
and function generator from the velocity controller to the force
controller by setting bit 8 (see Section 4.4).

4.14.1 Min/max display

Note
Machine data MD 5651 to MD 5654 are relevant only for internal Siemens
functions and must not be changed.

5651 MINMAX_SIGNAL_NR Cross ref.: –

Signal number of min/max memory Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 FFFF UNS.WORD Immediately
5652 MINMAX_ADDRESS Cross ref.: –
Memory location in min/max memory Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately

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5653 MINMAX_MIN_VALUE Cross ref.: –

Maximum value of min/max memory Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately
5654 MINMAX_MAX_VALUE Cross ref.: –
Maximum value of min/max memory Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately

4.14.2 Monitor

Note
Machine data MD 5655 to MD 5659 are relevant only for internal Siemens
functions and must not be changed.

5655 MONITOR_SEGMENT Cross ref.: –

Monitor memory location segment Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately
5656 MONITOR_ADDRESS Cross ref.: –
Monitor memory location address Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately
5657 MONITOR_DISPLAY Cross ref.: –
Monitor value display Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately
5658 MONITOR_INPUT_VALUE Cross ref.: –
Monitor value input Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFFFF UNS.WORD Immediately
5659 MONITOR_INPUT_STROBE Cross ref.: –
Monitor value transfer Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately

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4.14.3 Diagnostic machine data

A range of different machine data are provided in the HLA module for diagnostic
functions. NC diagnostic displays are available in a similar way to those used on
electrical drives.

5700 TERMINAL_STATE Cross ref.: –

Status of binary inputs Relevant for: Protection level:
Bit 0: 26.5 V supply available
HLA 3/3
Bit 1: Term. 663 available
Bit 2: Term. 63 available
Bit 3: Group signal HW enable available
Bit 5: Setup mode selected
Bit 6: Term. 64 available
Bit 12: 24 V for servo solenoid valve ON
Bit 13: 24 V for shutoff valve ON
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 0 0 FFFF UNS.WORD Immediately
5704 ACTUAL_PRESSURE_A Cross ref.: –
Actual pressure A Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 0.0 –10000.0 10000.0 FLOAT Immediately
5705 ACTUAL_PRESSURE_B Cross ref.: –
Actual pressure B Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 0.0 –10000.0 10000.0 FLOAT Immediately
5706 DESIRED_SPEED Cross ref.: –
Velocity setpoint Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 0.0 –240000.0 240000.0 FLOAT Immediately
5707 ACTUAL_SPEED Cross ref.: –
Actual velocity value Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 0.0 –240000.0 240000.0 FLOAT Immediately
5709 VOLTAGE_LSB Cross ref.: –
Significance of voltage representation Relevant for: Protection level:
Defines how many volts [V] correspond to 1 increment HLA 3/3
of the internal voltage format (valve spool setpoint/actual
value).
Unit: Default: Minimum: Maximum: Data type: Effective:
V 0.0 –100000.0 100000.0 FLOAT Immediately
5710 PRESSURE_LSB Cross ref.: –
Significance of pressure representation Relevant for: Protection level:
Defines the pressure in [bar] corresponding to 1 HLA 3/3
increment of the internal pressure format.
Unit: Default: Minimum: Maximum: Data type: Effective:
bar 0.0 –240000.0 240000.0 FLOAT Immediately

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5711 SPEED_LSB Cross ref.: –

Significance of velocity representation Relevant for: Protection level:
Defines the velocity in [mm/min] corresponding to 1 HLA 3/3
increment of the internal velocity format.
Unit: Default: Minimum: Maximum: Data type: Effective:
mm/min 0.0 –240000.0 240000.0 FLOAT Immediately
5713 FORCE_LSB Cross ref.: –
Significance force display Relevant for: Protection level:
Indicates the value to which one increment of the internal HLA 3/3
force corresponds in [µN].
Unit: Default: Minimum: Maximum: Data type: Effective:
µN 0.0 –10000000.0 10000000.0 FLOAT Immediately
5714 POSITION_LSB Cross ref.: –
Significance of position representation Relevant for: Protection level:
Define the position in [nm] corresponding to 1 increment HLA 3/3
of the internal position format.
Unit: Default: Minimum: Maximum: Data type: Effective:
nm 0.0 –1000000.0 1000000.0 FLOAT Immediately
5715 DESIRED_VALVE_SPOOL_POS Cross ref.: –
Voltage for valve spool position setpoint Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
V 0.0 –10.0 10.0 FLOAT Immediately
5716 ACTUAL_VALVE_SPOOL_POS Cross ref.: –
Voltage for actual valve spool position Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
V 0.0 –10.0 10.0 FLOAT Immediately
5725 MAX_FORCE_FROM_NC Cross ref.: –
Normalization of force setpoint interface Relevant for: Protection level:
Interface high-speed PLC data channel. HLA 3/3
Value corresponding to 4000hex in MD 5725.
Unit: Default: Minimum: Maximum: Data type: Effective:
N 0.0 0.0 10000000.0 FLOAT Immediately
5740 ACTUAL_POSITION Cross ref.: –
Actual position with respect to machine zero Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 –10000000.0 10000000.0 FLOAT Immediately
5741 ACTUAL_PISTON_POSITION Cross ref.: –
Piston position with respect to piston zero Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
mm 0.0 –10000000.0 10000000.0 FLOAT Immediately

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5730 OPERATING_MODE Cross ref.: –

Display of the operating mode Relevant for: Protection level:
Bit 0=1: Velocity controller active HLA 3/3
Bit 1=1: Force limitation active
Bit 2=1: Friction compensation active
Bit 3=1: Velocity controller adaptation active
Bit 4=1: Piston position known
Bit 8=1: Force limitation ON
Bit 9=1: Friction compensation ON
Bit 10=1: Simple force limitation ON
Unit: Default: Minimum: Maximum: Data type: Effective:
HEX 1 1 FFFF UNS.WORD Immediately
5790 ENC_TYPE Cross ref.: –
Measuring circuit type of measuring system Relevant for: Protection level:
0: IPU (V) unconditioned voltage signals HLA 3/3
1...15: Reserved
16: EnDat encoder
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 –1 32767 WORD Immediately
5720 CRC_DIAGNOSIS Cross ref.: –
CRC diagnostic parameter Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 FFFF UNS. WORD Immediately

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.

5708 ACTUAL_CYL_FORCE Cross ref.: –

Actual cylinder force Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
N 0.0 –10000000.0 10000000.0 FLOAT Immediately

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.

5717 DESIRED_CYL_FORCE Cross ref.: –

Cylinder force setpoint Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
N 0.0 –10000000.0 10000000.0 FLOAT Immediately

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4 Firmware Drive Functions 02.99
4.14 Service functions

If the force controller (force limitation or friction injection) has been activated in
MD 5241, the effective force setpoint is displayed here. It can be set by the
force limitation function (MD 5230 or 5231) or friction injection function (MD
5234 or MD 5235).
It must be noted that the force controller is activated only in conjunction with
friction injection and zero speed or with force limitation and violation of the upper
force limitation. The voltage setpoint of the velocity controller is otherwise ap-
plied, in which case the force setpoint is irrelevant.

Software version

5797 PBL_VERSION Cross ref.: –

Data version Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 FFFF UNS.WORD Immediately

Output of current data version (machine data list).

5798 FIRMWARE_DATE Cross ref.: –

Firmware date Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 FFFF UNS.WORD Immediately

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

5799 FIRMWARE_VERSION Cross ref.: –

Firmware version Relevant for: Protection level:
HLA
Unit: Default: Minimum: Maximum: Data type: Effective:
– 0 0 FFFFFF UNS.WORD Read Only

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

5735 PROCESSOR_UTILIZATION Cross ref.: –

Processor capacity utilization Relevant for: Protection level:
HLA 3/3
Unit: Default: Minimum: Maximum: Data type: Effective:
% 0 0 FFFF UNS. WORD Read only

The processor capacity utilization display provides online information about

available computing capacity.

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4.15 Table of parameters

4.15 Table of parameters

Default setting The machine data is preset to this value during start-up.

Value range Specifies the input limits. If no value range is indicated, the data byte deter-
(minimum and mines the input limits and the field is marked with “∗∗∗”.
maximum value)

Effectiveness of
changes
S POWER ON (po) “RESET” key on front panel of the NCU module
or disconnection and reconnection of power supply
of softkey “NCK Reset”

S NEW_CONF (cf) – Softkey “Set MD active” on MMC

– “RESET” key on control unit,
– Changes can be made in program mode at block
limits

S RESET at end of program M2/M30

S RESET (re) “RESET” key on control unit or

S Immediately (im) after entry of the value

The levels of effectiveness have been listed above in order of priority.

Protection level Protection levels 0 to 7 have been used. The lock for protection levels 0 to 3 (4
to 7) can be cancelled by entering the correct password (setting correct key-
switch position). The operator has access to the information on the level to
which he has authorization and to all lower levels.
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

Unit The unit is referred to the default setting of machine data

SCALING_FACTOR_USER_DEF_MASK and
SCALING_FACTOR_USER_DEF.
If the MD is not based on any physical unit, then the field is labelled with “–”.

Index Selectable data sets associated with one parameter.

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4.15 Table of parameters

Data type The following data types are used in the control system:

S BOOLEAN Machine data bit (1 or 0)

S BYTE Integers (from –128 to +127)

S DOUBLE Real values or integers

(from +/–4.19*10–307 to +/–1.67*10308)

S DWORD Integers (from –2.147*109 to +2.147*109)

S STRING Character string (max. 16 characters) consisting of

capital letters with digits and underscore

S UNSIGNED WORD Integers (from 0 to 65536)

S SIGNED WORD Integers (from –32768 to 32767)

S UNSIGNED DWORD Integers (from 0 to 4294967300)

S SIGNED DWORD Integers (from –2147483650 to 2147483649)

S WORD Hex values (from 0000 to FFFF)

S DWORD Hex values (from 00000000 to FFFFFFFF)

S FLOAT DWORD Real values (from “8.43*10-37 to “3.37*1038)

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 Attributes Chap./ Firm-
MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective
08.99
02.99

version
5001 Velocity controller cycle SPEEDCTRL_CYCLE_TIME 4 2 16 31.25 µ s UNS.WORD Power On 4.3.2 1.01
5004 Configuration structure CTRL_CONFIG 1000 0 1000 HEX UNS.WORD Power On 4.3.1 1.01

5008 Encoder phase error compensation 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

5021 Multi-turn resolution absolute encoder in motor ENC_ABS_TURNS_MOTOR 4096 0000 65535 U WORD Power On 4.10 1.01

5022 Measuring steps of absolute track in motor ENC_ABS_RESOL_MOTOR 8192 0000 65535 – WORD 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

 Siemens AG 2000. All rights reserved

5024 Linear scale graduations DIVISION_LIN_SCALE 20000 1000 5000000 nm UNS.DWORD Power On 4.10 1.01
5040 Piston zero in relation to machine zero PISTON_ZERO 0.0 –1000000.0 100000.0 mm FLOAT Immediately 4.10 1.01

5100 Modulus of elasticity of hydraulic fluid FLUID_ELASTIC_MODULUS 11000 1000 21000 bar FLOAT Immediately 4.6 1.01

5101 System pressure WORKING_PRESSURE 0.0 0.0 350.0 bar FLOAT Power On 4.6 1.01

5102 Pilot pressure PILOT_OPERATION_PRESSURE 0.0 0.0 250.0 bar FLOAT Immediately 4.6 1.01

5106 Valve code number VALVE_CODE 0 0 2000 – UNS.WORD Immediately 4.7 1.01

5107 Rated valve flow VALVE_NOMINAL_FLOW 0.0 0.0 1000.0 l/min FLOAT Immediately 4.7 1.01

5108 Rated pressure drop of valve VALVE_NOMINAL_PRESSURE 35.0 1.0 200.0 bar FLOAT Immediately 4.7 1.01

5109 Rated voltage of valve VALVE_NOMINAL_VOLTAGE 10.0 0.5 15.0 V FLOAT Immediately 4.7 1.01

5110 Valve knee-point voltage 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

5112 Valve flow ratio betw. A and B ends VALVE_FLOW_FACTOR_A_B 1.0 0.5 2.0 – FLOAT Immediately 4.7 1.01

5113 Valve configuration VALVE_CONFIGURATION 0 0 13 HEX UNS.WORD Immediately 4.7 1.01

5114 Natural frequency of valve VALVE_NATURAL_FREQUENCY 150.0 1.0 1000.0 Hz FLOAT Immediately 4.7 1.01

1.01

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
5115 Valve damping VALVE_DAMPING 0.8 0.4 1.0 – FLOAT Immediately 4.7
5131 Cylinder piston diameter CYLINDER_PISTON_DIAMETER 0.0 0.0 500.0 mm FLOAT Power On 4.8 1.01

5132 Cylinder piston rod diameter A CYLINDER_ROD_A_DIAMETER 0.0 0.0 500.0 mm FLOAT Power On 4.8 1.01

5133 Cylinder piston rod diameter B CYLINDER_ROD_B_DIAMETER 0.0 0.0 500.0 mm FLOAT Power On 4.8 1.01

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
4 Firmware Drive Functions
4.15 Table of parameters

4-165
 Attributes Chap./ Firm-
MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective

4-166
version
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 20000.0 kg FLOAT Immediately 4.9 1.01
4.15 Table of parameters
4 Firmware Drive Functions

5151 Cylinder mounting position referred to A end CYLINDER_A_ORIENTATION 0.0 -90.0 90.0 Degr. 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
5210 Blocking freq. control output filter 1 velocity contr. 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 Numerator bandw. contr. output filter 1 vel. contr. 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 velocity contr. 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 Numerator bandw. contr. output filter 2 vel. contr. 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
08.99
02.99

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 Siemens AG 2000. All rights reserved
 Attributes Chap./ Firm-
MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective
08.99
02.99

version
5232 Velocity threshold for static friction STICTION_SPEED_THRESHOLD 10.0 0.0 500.0 mm/min FLOAT Immediately 4.4.2 1.01
5233 Cutoff limit static friction STICTION_COMP_THRESHOLD 40.0 3.0 100.0 % FLOAT Immediately 4.4.2 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 gain FORCECTRL_GAIN_RED 40.0 0.1 100.0 % FLOAT Immediately 4.4.3 1.01

 Siemens AG 2000. All rights reserved

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

5246 Force controller D-action time FORCECTRL_DIFF_TIME 0.0 –10000.0 10000.0 ms FLOAT 0...7 Immediately 4.4.3 1.01
5247 Feedforward control factor for force controller FORCE_FFW_WEIGHT 100.0 0.0 120.0 % FLOAT 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

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 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 control output filter 1 OUTPUT_FIL_1_DAMP 1.0 0.05 1.0 – FLOAT 0...7 Immediately 4.5.2 1.01

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
5288 Blocking frequency 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 control output filter 1 OUTPUT_FIL_1_BW 500.0 5.0 7999.0 Hz FLOAT 0...7 Immediately 4.5.2 1.01

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

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
4 Firmware Drive Functions
4.15 Table of parameters

4-167
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MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective

4-168
version
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 50.0 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
4.15 Table of parameters
4 Firmware Drive Functions

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 lead time SPEEDCTRL_DIFF_TIME 0.0 -100.0 100.0 ms FLOAT 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 Immediately 4.3.2 1.01

5435 Controlled system gain CONTROLLED_SYSTEM_GAIN 0.0 0.0 20000.0 mm/Vmin FLOAT 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

5462 Piston surface adaptation factor, positive AREA_FACTOR_POS_OUTPUT 100.0 50.0 200.0 % FLOAT Immediately 4.5.1 1.01
5463 Piston surface adaptation factor, negative AREA_FACTOR_NEG_OUTPUT 100.0 50.0 200.0 % FLOAT Immediately 4.5.1 1.01
5464 Knee-point compensation pos. flow POS_DUAL_GAIN_COMP_FLOW 10.0 0.2 95.0 % FLOAT Immediately 4.5.1 1.01

5465 Knee-point compensation pos. voltage POS_DUAL_GAIN_COMP_VOLTAGE 10.0 0.2 95.0 % FLOAT Immediately 4.5.1 1.01

5466 Rounding range for knee-point compensation DUAL_GAIN_COMP_SMOOTH_RANGE 2.5 0.0 10.0 % FLOAT Immediately 4.5.1 1.01
5467 Knee-point compensation neg. flow NEG_DUAL_GAIN_COMP_FLOW 10.0 0.2 95.0 % FLOAT Immediately 4.5.1 1.01
5468 Knee-point compensation neg. voltage NEG_DUAL_GAIN_COMP_VOLTAGE 10.0 0.2 95.0 % FLOAT 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 OUTPUT_VOLTAGE_LIMIT 10.0 1.0 10.0 V FLOAT Immediately 4.5.3 1.01
08.99
02.99

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 Siemens AG 2000. All rights reserved
 Attributes Chap./ Firm-
MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective
08.99
02.99

version
5476 Manipulated variable inversion OUTPUT_VOLTAGE_INVERSION 0 0 1 – UNS.WORD 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 Immediately 4.5.1 1.01

5481 Knee-point compens. pos. voltage in zero range POS_DUAL_GAIN_COMP_Z_VOLT 0.0 0.0 95.0 % FLOAT Immediately 4.5.1 1.01

5482 Knee-point compensation rounding zero range DUAL_GAIN_COMP_SMOOTH_Z_R 0.0 0.0 10.0 % FLOAT 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 Immediately 4.5.1 1.01

5484 Knee-point compens. neg. voltage in zero range NEG_DUAL_GAIN_COMP_Z_VOLT 0.0 0.0 95.0 % FLOAT 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 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 Immediately 4.5.1 1.01

 Siemens AG 2000. All rights reserved

5487 Knee-point compensation neg. flow saturation NEG_DUAL_GAIN_COMP_S_FLOW 100.0 0.2 100.0 % FLOAT 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 Immediately 4.5.1 1.01

5500 No. 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

5520 Band-stop filter natural frequency for velocity filter 1 SPEED_FILTER_1_BS_FREQ 100.0 1.0 141.0 % FLOAT 0...7 Immediately 4.3.1 1.01

5530 Safety configuration CYLINDER_SAFETY_CONFIG 4 0 31 HEX UNS.WORD Immediately 4.12 1.01

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

5550 Reference value of pressure sensor A at 10 V PRESSURE_SENS_A_REF 200.0 50.0 400.0 bar FLOAT Immediately 4.11 1.01

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
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 50.0 400.0 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
4 Firmware Drive Functions
4.15 Table of parameters

4-169
 Attributes Chap./ Firm-
MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective

4-170
version
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
5612 Config. shutdown reaction to PO alarms ALARM_REACTION_POWER_ON 0 0 FFFF HEX UNS.WORD Immediately 4.13 1.01
4.15 Table of parameters

5613 1.01
4 Firmware Drive Functions

Config. shutdown reaction to RESET alarms ALARM_REACTION_RESET 0 0 FFFF HEX UNS.WORD Immediately 4.13
5614 Valve spool monitoring timer VALVE_ERROR_TIME 50 1 100 ms UNS.WORD Immediately 4.13 1.01
5620 Bits of variable signalling functions PROG_SIGNAL_FLAGS 0 0 7 HEX UNS.WORD Immediately 4.13 1.01

5621 Signal number of variable signalling 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.DWORD Immediately 4.13 1.01
5623 Threshold for variable signalling functions PROG_SIGNAL_THRESHOLD 0 0 FFFFFF HEX UNS.DWORD Immediately 4.13 1.01
5624 Hysteresis for variable signalling functions PROG_SIGNAL_HYSTERESIS 0 0 FFFFFF HEX UNS.DWORD Immediately 4.13 1.01
5625 Dropout delay for variable signalling function PROG_SIGNAL_ON_DELAY 0 0 10000 – UNS.WORD Immediately 4.13 1.01

5626 Dropout delay for variable signalling function PROG_SIGNAL_OFF_DELAY 0 0 10000 – UNS.WORD Immediately 4.13 1.01

5650 Diagnostic control DIAGNOSIS_CONTROL_FLAGS 0 0 FFFF HEX UNS.WORD Immediately 4.14 1.01

5651 Signal number of min/max memory MINMAX_SIGNAL_NR 0 0 FFFF – UNS.WORD Immediately 4.14 1.01

5652 Memory location in min/max memory MINMAX_ADDRESS 0 0 FFFFFF HEX UNS.DWORD Immediately 4.14 1.01
5653 Minimum value of min/max memory MINMAX_MIN_VALUE 0 0 FFFFFF HEX UNS.DWORD Immediately 4.14 1.01

5654 Maximum value of min/max memory MINMAX_MAX_VALUE 0 0 FFFFFF HEX UNS.DWORD 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.DWORD Immediately 4.14 1.01

5657 Monitor value display MONITOR_DISPLAY 0 0 FFFFFF HEX UNS.DWORD Immediately 4.14 1.01

5658 Monitor value input MONITOR_INPUT_VALUE 0 0 FFFFFF HEX UNS.DWORD Immediately 4.14 1.01

5659 Monitor value transfer MONITOR_INPUT_STROBE 0 0 FFFF HEX UNS.WORD Immediately 4.14 1.01
08.99
02.99

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 Siemens AG 2000. All rights reserved
 Attributes Chap./ Firm-
MD No. Name in plaintext Name in NC Version Min. Max. Unit Data type Sect. ware
Index Effective
08.99
02.99

version
5700 Status of binary inputs TERMINAL_STATE 0 0 FFFF 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

 Siemens AG 2000. All rights reserved

5711 Significance velocity representation SPEED_LSB 0.0 -240000.0 240000.0 mm/min FLOAT Immediately 4.14 1.01

5713 Significance of force representation FORCE_LSB 0.0 -10000000.0 10000000.0 µN 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 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

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

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
5797 Data version PBL_VERSION 0 0 FFFF – UNS.WORD Immediately 4.14 1.01
5798 Firmware date FIRMWARE_DATE 0 0 FFFF – UNS.WORD Immediately 4.14 1.01

5799 Firmware version FIRMWARE_VERSION 0 0 FFFFFF – UNS.DWORD Immediately 4.14 1.01

4 Firmware Drive Functions
4.15 Table of parameters

4-171
4 Firmware Drive Functions 08.99
02.99
4.15 Table of parameters

Notes

 Siemens AG 2000. All rights reserved

4-172 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Hardware Drive Functions 5

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 5-173
5 Hardware Drive Functions 02.99
5.1 Overview of interfaces

5.1 Overview of interfaces

Measuring system
(encoder connection)

Pressure sensor

Servo solenoid
valve

DACs

Drive bus

Device bus

Fig. 5-1 HLA closed-loop control plug-in module (2-axis)

 Siemens AG 2000. All rights reserved

5-174 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 5 Hardware Drive Functions
5.1 Overview of interfaces

Axis 1 Axis 2
F1900 F1901

Fig. 5-2 Location diagram of HLA closed-loop control module

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 5-175
5 Hardware Drive Functions 02.99
5.1 Overview of interfaces

5.1.1 Measuring system

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 inserted in the connector of the associ-
ated axis.
For further information, please see Section 7.1.

Table 5-1 PlugX101, X102; in each case15-pole subminiature D plug (two-tier)

Pin X101 X102 Function

1 PENC0 PENC2 Encoder power supply
2 M M Encoder power supply ground
3 AP0 AP2 Incremental signal A
4 AN0 AN2 Inverse incremental signal A
5 BMIDAT0 BMIDAT2 Data signal, EnDat interface
6 BP0 BP2 Incremental signal B
7 BN0 BN2 Inverse incremental signal B
8 XBMIDAT0 XBMIDAT2 Inverse data signal, EnDat interface
9 PSENSE0 PSENSE2 Remote Sense encoder power supply (P)
10 RP0 RP2 Incremental signal R
11 MSENSE0 MSENSE2 Remote Sense encoder power supply (M)
12 RN0 RN2 Inverse incremental signal R
13 M M Ground (for internal shields)
14 BMICLK0 BMICLK2 Clock signal, EnDat interface
15 XBMICLK0 XBMICLK2 Inverse clock signal, EnDat interface

 Siemens AG 2000. All rights reserved

5-176 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 5 Hardware Drive Functions
5.1 Overview of interfaces

5.1.2 Pressure sensors

Connection for 2 pressure sensors for each axis

S X111: Axis 1 (sensor 1A, 1B)

S X112: Axis 2 (sensor 2A, 2B)

Table 5-2 Connectors X111, X112; 15-pin subminiature D female connector in each
case

Pin X111 X112 Function

1 P24DS P24DS Supply of pressure sensor with external +24 V voltage
2 P24DS P24DS Supply of pressure sensor with external +24 V voltage
3 – – Not assigned
4 – – Not assigned
5 M24EXT M24EXT Supply of pressure sensor with external 0 V voltage
6 – – Not assigned
7 – – Not assigned
8 – – Not assigned
9 M24EXT M24EXT Supply of pressure sensor with external 0 V voltage
10 M24EXT M24EXT Extra pin for jumper betw. pins 10–11 with 3-wire con-
nection
11 PIST1BN PIST2BN Analog actual-value signal, reference ground
12 PIST1BP PIST2BP Analog actual-value signal, max. range 0...10 V
13 M24EXT M24EXT Extra pin for jumper betw. pins 13–14 with 3-wire con-
nection
14 PIST1AN PIST2AN Analog actual-value signal, reference ground
15 PIST1AP PIST2AP Analog actual-value signal, max. range 0...10 V

The inputs are differential with 40 kΩ input resistance.

The input voltage range is 0...+10 V.
The supply output has electronic short-circuit protection.
The supply output is rated for a total current (4 sensors) of 200 mA.
Power supply of pressure sensors at 26.5 V 2 % according to external supply.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 5-177
5 Hardware Drive Functions 02.99
5.1 Overview of interfaces

5.1.3 Servo solenoid valve

S X121: Axis 1

S X122: Axis 2

Table 5-3 Connectors X121, X122; both are 15-pin subminiature D female connec-
tors

Pin X121 X122 Function

1 P24RV1 P24RV2 +24 V switched
2 P24RV1 P24RV2 +24 V switched
3 P24RV1 P24RV2 +24 V switched
4 P24RV1 P24RV2 +24 V switched
5 M M Electronics ground
6 USOLL1N USOLL2N Analog setpoint output, reference ground
7 USOLL1P USOLL2P Analog setpoint output +/–10 V
8 M M Electronics ground
9 M24EXT M24EXT External 24 V ground
10 M24EXT M24EXT External 24 V ground
11 M24EXT M24EXT External 24 V ground
12 – – Not assigned
13 M M Electronics ground
14 UIST1N UIST2N Analog valve actual-value input, reference ground
15 UIST1P UIST2P Analog valve actual-value input, +/–10 V

The analog valve actual value inputs are differential with 100 kΩ input
resistance.
The current ratings of the 24 V outputs on the servo solenoid value are

S at ambient temperature 40 °C 2.0 A

S at ambient temperature 55 °C 1.5 A

for the mean current value with a load cycle of 10 s duration.
The temperature corner points may be interpolated linearly.
The short-term current rating of the servo solenoid valve outputs is 3.0 A (200
ms).
In the event of overload, fuse F1900 or F1901 on the HLA closed-loop control
plug-in module (for position, see Fig. 5-2) will blow.

Fuse protection The 24 V outputs switched for axes 1 and 2 are protected by miniature fuses,
i.e. fuse type F1900 for axis 1 and F1901 for axis 2.
Value: 2.5 AF/250 V; 5x20 mm UL
Company: Wickmann-Werke GmbH
Annenstrasse 113
D-58453 Witten
or
P.O. Box 2520
D-58415 Witten, Germany
Order No.: 19194

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04.00
02.99 5 Hardware Drive Functions
5.1 Overview of interfaces

5.1.4 Terminals
Shutoff valves (axis-specific), external 26.5 V supply, enabling, BERO inputs
S X431: Axis 1
S X432: Axis 2

Table 5-4 Connector X431; 8-pin Phoenix Combicon connector

Pin X431 Type1) Function Typ. voltage/

limit values
1 M E Electronics ground
2 PV1 A +24V shutoff valve axis 1 max. 2.0 A
3 MV1 A Ground for shutoff valve for axis 1
4 C1 – Reserved, do not use!
5 P24 E Input for +24 V external 26.5 V 2 %
6 M24 E Input 0 V external
7 663 E Module-specific enable signal 21 V...30 V
8 9 A Internal +24 V enable voltage, term. 9

Table 5-5 Connector X432; 8-pin Phoenix Combicon connector

Pin X432 Type1) Function Typ. voltage/

limit values
1 M E Electronics ground
2 PV2 A +24V shutoff valve axis 2 max. 2.0 A
3 MV2 A Ground for shutoff valve for axis 2
4 C2 – Reserved, do not use!
5 B1 E BERO input, axis 1 13 V...30 V
6 19 A Internal enable voltage ground, term.19
7 B2 E BERO input, axis 2 13 V...30 V
8 9 A Internal +24 V enable voltage, term. 9

Max. terminal cross-section 2.5 mm2.

The +24 V outputs for shutoff valves for axes 1 and 2 are short-circuit-proof.
The energy absorbed when inductive loads are disconnected must be limited to
1.7 J by the user (see also Section 2.4.2). When the supply polarity is reversed,
the outputs are not protected against overload.

Warning
! If the polarity of the 24 V supply is reversed, then the shutoff valves will open
immediately, even if the NC or closed-loop control is not in operation!

1) E=input; A=output

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5 Hardware Drive Functions 04.00
02.99
5.1 Overview of interfaces

Note
Each of the shutoff 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 for the supply of BEROs
and terminal 663 and must not be used to supply hydraulics components. The
hydraulics components must be supplied via incoming supply P24. The volt-
ages 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 applied additionally to the shutoff valves.
The enable voltage can be picked off at terminal 9.
Terminal 663 is referred to the internal enabling voltage (ground, terminal 19).

5.1.5 Test sockets (diagnosis)

Test sockets Using the Start-Up Tool or an MMC102/103, it is possible to assign internal sig-
nals to the test sockets on the 611D drive (in conjunction with SINUMERIK
840D), where the signals are then available as analog values (see also Section
3.11).

DAC1 DAC2

DAC3 Ground

Scope of functions 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.

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04.00
02.99 5 Hardware Drive Functions
5.1 Overview of interfaces

Bit 23 16 15 8 7 0 (LSB)

DAC with SF0

DAC with SF1

DAC with SF8

DAC with SF16

LSB = Least Significant Bit SF = Shift factor

Fig. 5-3 Representation of shift factor

Activation of The screen for activating and parameterizing the DAC outputs can be reached
analog output from the basic machine display via softkeys Start-up /
Drive/servo / DAC config.
The configuration is activated with Start. Active DACs are identified (active/inac-
tive) on the left of the screen. The output is terminated with Stop (active/inac-
tive) .
The selected signals are active after POWER ON.

Output voltage The DAC operates on a voltage of between 0 V and +5 V. In this case, the 2.5 V
range output voltage corresponds to the zero of the displayed signal. A two’s comple-
ment is used in the digital/analog conversion, see Fig. 5-3.

7FHex ( 0111 1111d)

+5V

UDAC
00Hex
2.5V
00Hex FFHex

0V
80Hex (1000 0000d)

Fig. 5-4 Analog output voltage range

5.1.6 Bus interfaces

Drive bus (see SIMODRIVE 611A/D)

S X141: Input
S X341: Output
A bus terminator must be inserted in the last module.

Device bus (see SIMODRIVE 611A/D)

S X151: Device bus

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5 Hardware Drive Functions 02.99
5.2 System environment

5.2 System environment

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 an NE module as an extended
power supply). No provision has been made for any other type of voltage 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!

Power is supplied to downstream electrical axes via the DC link busbars

(40 mm2) of the carrier module.
For information about the electrical supply conditions for the NE or ÜW module,
as well as circuit recommendations, technical data and setting options, please
refer to Section 2 and
References: /PJ2/ SIMODRIVE Planning Guide

X101
X102
X111
X112
X121
X122
X35 Bus terminator
X34
Drive bus

Device bus

SIEMENS

SIMODRIVE

NE module NCU HLA

(840D)

Fig. 5-5 Component layout for hydraulic drive

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02.99 5 Hardware Drive Functions
5.3 Additional information

5.3 Additional information

5.3.1 Climatic and mechanical environmental conditions in operation

Note
The following information refers to the electrical section of the HLA.

Applicable IEC 68-2-1, IEC 68-2-2, IEC 68-2-3

standards

Climatic If the specified values cannot be maintained, then a heat exchanger or air con-
environmental ditioner must be provided.
conditions
Table 5-6 Climatic environmental conditions

Temperature range Lower limit temperature 0°C

Upper limit temperature +55°C 1)
Dew-point temperature td Yearly average U = 75%, td = 17°C
and relative air humidity U
On 30 days (24 hours) in U = 95%, td = 24°C
year (days distributed over
the annual period)
On other days (<24 hours) U = 85%, td = 20°C
(observing the yearly aver-
age)
Condensation Not permissible
Temperature change Within one hour 10 K
Within three minutes 1K
Air pressure At installation site up to 86 kPa to 108 kPa
1500 m above sea level. In
the case of higher height
values, the upper limit tem-
perature must be reduced
by 3.5°C/500m.

Table 5-7 Mechanical environmental conditions

Vibration resistance Frequency range Constant deflection

(acc. to IEC 68-2-6) 10–58 Hz 0.075 mm
Ampl. of acceleration
9.8 m/s2
above 58–500 Hz
Shock resistance in op- Acceleration 5g
eration
Duration of nominal shock 11 ms for device without
(test group E, test Ea ac-
disk drive
cording to IEC 68, Part
30 ms for device with disk
2-27)
drive

1) Current reduction above 40°C at the servo valve output, see Section 5.1.3.

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5 Hardware Drive Functions 02.99
5.3 Additional information

5.3.2 Shipment and storage conditions

Note
The following information refers to the electrical section of the HLA.

Applicable IEC 68-2-1, IEC 68-2-2, IEC 68-2-3

standards

Originally The following data applies to modules in their original packaging:

packaged modules
Table 5-8 Climatic conditions

Temperature range Lower limit temperature –40°C

Upper limit temperature +70°C
Dew-point temperature td Yearly average U = 75%, td = 17°C
and relative air humidity U
On 30 days (24 hours) in U = 95%, td = 24°C
year (days distributed over
the annual period)
On 30 days (24 hours) in U = 85%, td = 20°C
year (days distributed over
the annual period)
Condensation Seldom, brief, slight
As regards condensation,
the following conditions may
apply simultaneously:
Max. condensation period 3 hours
Frequency of condensation Yearly average: 3 / Max.: 10
Shortest sequence of con- 1 day
densation cycles
Temperature change Within one hour 20 K
Air pressure The specified values apply 66 kPa to 108 kPa
to a shipment altitude of up
to 3265 m above sea level

Table 5-9 Mechanical conditions for shipment in original packaging

Vibration resistance Frequency range Const. deflection

(to IEC 68-2-6) 5–9 Hz 3.5 mm
Ampl. of acceleration
above 9–500 Hz 10 m/s2

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02.99 5 Hardware Drive Functions
5.3 Additional information

5.3.3 Resistance to pollutants

Relevant DIN 40046, Parts 36 and 37

standards
Table 5-10 Harmful gases

Sulphur dioxide (SO2)

Test conditions: Degree of severity 10 cm3/m3 0.3 cm3/m3
Temperature 25 °C 2 °C
Relative air humidity 75% 5%
Duration 4 days

Hydrogen sulfide (H2S)

Test conditions: Degree of severity 1 cm3/m3 0.3 cm3/m3

Temperature 25 °C 2 °C
Relative air humidity 75% 5%
Duration 4 days

Harmful dust If the control is to be operated in an area exposed to harmful dust, it must be
installed in a cubicle with heat exchanger or with an adequate supply of cooling
air.

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5 Hardware Drive Functions 02.99

Notes

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5-186 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Hydraulics Diagnostics 6
Error reactions When an error occurs, the system reacts with either a power disable or velocity
controller disable depending on the error type.
The power is disabled as a reaction to errors which might make operation under
closed-loop control impossible, such as

S velocity controller at limit,

S measuring system error,
S RAM checkerror,
S drive computer crash, etc.

Scope The alarms which are specifically related to the hydraulics module are listed
below:
Other alarms may also occur and are described in:
References: /DA/, Diagnostics Guide
For special cases arising in conjunction with an integrated PLC, please refer to
documentation of the SIMATIC S7-300 System.

Alarm order The alarms are listed in order of ascending alarm number. There are gaps in the
alarm numbering sequence. The sequence is not without gaps.

Structure of alarm Each alarm, consisting of an alarm number and alarm text, is described with 4
description categories:
S Explanation
S Reaction
S Remedy
S To continue program

Safety

Danger
! Please check the situation in the plant on the basis of the description of the
active alarm(s). Eliminate the cause of the alarm(s) and give the appropriate
acknowledgement. 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 alarms with error numbers 300 000 to 300 499, please
refer to documentation
300 499
References: /DA/, Diagnostics Guide

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6 Hydraulics Diagnostics 02.99

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 signals a system error. For an exact breakdown of error codes, see
/FBA/ DB1, Operational Messages/Alarm Reactions.
Reaction NC not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Re-initilization of drive.
The exact cause of the error can only be located by the development team. The
developers must be notified of the displayed error identifiers.
SIEMENS AG, After-Sales Support for A&D MC Products, Hotline.
To continue Switch control system OFF and ON again.
program

300 504 Axis %1, drive %2 measuring circuit error motor measuring system
Explanation %1 = NC axis number
%2 = drive number
Signal level of motor encoder too small or noisy.
Reaction Mode group not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Start disable.
NC Stop in response to alarm.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
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 closed-loop 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.).
To continue Switch control system OFF and ON again.
program

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02.99 6 Hydraulics Diagnostics

300 506 Axis %1, drive %2, no sign of life from NC

Explanation %1 = NC axis number
%2 = drive number
With the controllers enabled, the NC must update its sign of life in every position
controller cycle. The sign of life has not been updated in the event of a distur-
bance.
Cause:
a) NC no longer updates its sign of life in reaction to an alarm
(e.g. 611D alarm)
b) Fault in communication link via the drive bus
c) Hardware fault on drive module
d) NC fault
e) On 840D: Setting in machine data MD10082:
MN_CTRLOUT_LEAD_TIME (offset in setpoint transfer time)
is too high
The alarm can be reconfigured in MD 11412: ALARM_REACTION_CHAN_NO-
READY (channel not ready).
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Re: a) Check whether the sign of life failure is a secondary error. A secondary
error is defined, for example, as:
fault / alarm on axis x in an n-axis configuration. If the error
is of this type, then the above error message is signalled for all n axes,
even though the fault / alarm applies only to axis x.
==> Eliminate cause of error on axis x
==> Sign of life of other axes is irrelevant
Re: b) Check plug-in connections, take measures to suppress RI (check
shielding, ground connections)
Re: c) Replace closed-loop control module
Re: d) See NC error diagnosis, replace NC hardware if necessary
Re: e) Set machine data 840D MD10082: CTRLOUT_LEAD_TIME
(offset in setpoint transfer time) to correct value using
machine data MD10083: CTRLOUT_LEAD_TIME_MAX
(maximum settable offset in setpoint transfer time).

To continue Switch control system OFF and ON again.

program

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6 Hydraulics Diagnostics 02.99

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 in MD 11412: ALARM_REACTION_CHAN_NO-
READY (channel not ready).
Reaction Mode group not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.

Remedy Please inform authorized personnel/service engineer.

Use original Siemens pre-assembled encoder cables (high degree of shield
protection).
Check encoder, encoder cable for cable break and shield bonding point. Check
shield bonding point on front plate (top screw), replace closed-loop control mod-
ule if necessary.
Check distance between gear wheel and sensor on gear wheel encoders. If a
BERO is installed, it is not the BERO signal which is monitored, but the zero
marker of the encoder.
To continue Switch control system OFF and ON again.
program

300 511 Axis %1, drive %2 measuring function active

Explanation %1 = NC axis number
%2 = drive number
The measuring function (e.g. frequency response measurement) was active as
the power supply was connected (power-up).
The function might have been started illegally.
Reaction NC not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.

Remedy Stop the measuring function

NCK Reset
To continue Switch control system OFF and ON again.
program

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02.99 6 Hydraulics Diagnostics

300 701 Start-up required for axis %1, drive %2

Explanation %1 = NC axis number
%2 = drive number
This alarm occurs during initial start-up when no valid 611D machine data are
available!
Reaction NC not ready.
Mode group not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.

S Boot the motor data

S Back up the BOOT drive
S Power up system again
To continue Switch control system OFF and ON again.
program

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.
Reaction NC not ready.
Mode group not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy No remedial measures need to be taken. 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.
To continue Switch control system OFF and ON again.
program

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 in connection with OEM users who are using a 611D
drive without the standard NCK interface. In this instance, it is possible to trans-
fer different axial drive clock cycles to the 611D modules.

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6 Hydraulics Diagnostics 02.99

Reaction NC not ready.

Mode group not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Set drive basic clock cycle to the same value for both axes.
To continue Switch control system OFF and ON again.
program

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 mod-
ule.
This alarm can only occur in connection with OEM users who are using 611D
drives without the standard NCK interface. In this instance, it would be possible
to transfer different axial position controller clock cycles to the 611D module.
Reaction NC not ready.
Mode group not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Set position controller cycle to the same value for both axes.
To continue Switch control system OFF and ON again.
program

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 integral multiple
of the speed controller cycle.
Reaction NC not ready.
Mode group not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Correct MD 10082: CTROUT_LEAD_TIME (offset in setpoint transfer time).
To continue Switch control system OFF and ON again.
program

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02.99 6 Hydraulics Diagnostics

300 754 Axis %1, drive %2 signal number var. signalling function invalid
Explanation %1 = NC axis number
%2 = drive number
The signal number for output of the appropriate signalling function is illegal. The
permissible signal number range starts at 0 and ends at 29.
Reaction NC not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Enter the correct signal number.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

300 770 Axis %1, drive %2 format error

Explanation %1 = NC axis number
%2 = drive number
The calculated filter coefficients for a bandstop cannot be represented in the
internal format.
The alarm can be reconfigured in MD 11412: ALARM_REACTION_CHAN_NO-
READY (channel not ready).
Reaction NC not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.
Change the filter setting.
Troubleshooting for the exact error cause can be supported by Hotline staff. Call
SIEMENS AG, SIMODRIVE Hotline.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

300 799 Axis %1, drive %2 save and boot necessary

Explanation %1 = NC axis number
%2 = drive number
After drive machine data have been modified, parameters need to be re-calcu-
lated. The calculation routine is started with softkey CALCULATE. After the con-
trol parameters have been calculated, the machine data must be saved and the
system powered up again.
The alarm can be reconfigured in MD 11412: ALARM_REACTION_CHAN_NO-
READY (channel not ready).

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6 Hydraulics Diagnostics 08.99
02.99

Reaction Switchover for entire channel via MD might be possible.

NC not ready.
Mode group not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The newly calculated data must be saved (softkey: SAVE).
The new parameter settings become operative when the system is next booted!
To continue Switch control system OFF and ON again.
program

300 854 Axis %1, drive %2 signal number var. signalling function invalid
Explanation %1 = NC axis number
%2 = drive number
The signal number for output of the appropriate signalling function is illegal. The
permissible signal number range starts at 0 and ends at 29.
Reaction Alarm display.
Interface signals are set.
Remedy Enter the correct signal number.
To continue Alarm display disappears with alarm cause. No further operator action required.
program

310 505 Axis %1, drive %2 meas. circuit error abs. track, code %3
Explanation %1 = NC axis number
%2 = drive number
%3 = error fine coding
Absolute encoder (EQN 1325)
Monitoring of encoder hardware and EnDat interface.
Exact diagnosis via error code MD5023: ENC_ABS_DIAGNOSIS_MOTOR
(diagnosis of absolute track in motor meas. circuit):

Bit No. Meaning Note

Bit 0 Lighting failure
Bit 1 Signal amplitude too low
Bit 2 Code connection faulty
Bit 3 Overvoltage
Bit 4 Undervoltage
Bit 5 Overcurrent
Bit 6 Battery must be replaced
Bit 7 CRC error (evaluate bit 13 as well) see 1)
Bit 8 Encoder cannot be used
Illegal assignment between
absolute and incremental tracks
Bit 9 C/D track on ERN1387 encoder
faulty or EQN encoder connected

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02.99 6 Hydraulics Diagnostics

Bit No. Meaning Note

Bit 10 Protocol cannot be interrupted
Bit 11 SSI level in data line detected
Bit 12 TIMEOUT on measured value
reading
Bit 13 CRC error (evaluate bit 7 as well) see 1)
Bit 14 Unassigned
Bit 15 Encoder defective

1)
CRC error: Bits 7 and 13 Meaning:
0 1 CRC error from SIDA-ASIC
1 0 Check byte error
1 1 Error in correction of absolute track by
incremental track
Response Mode group not ready.
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Start disable.
NC Stop in response to alarm.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Please inform authorized personnel/service engineer.

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.-

S Replace motor and cable if necessary

S Incorrect cable type
S Closed-loop control hardware unsuitable for Endat interface (e.g. closed-
loop plug-in module with EPROM).
To continue Switch control system OFF and ON again.
program

310 607 Axis %1, drive %2 valve is not responding

Explanation %1 = NC axis number
%2 = drive number
The valve is not following the valve spool setpoint.
Cause: Valve is not connected or has no valve spool checkback signal.
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 6-195
6 Hydraulics Diagnostics 02.99

Remedy Valve without valve spool checkback: MD 5530: Reset bit 2;

Check valve connections.
To continue Cancel alarm in all channels of this mode group by pressing RESET key. Re-
program start the part program.

310 608 Axis %1, drive %2 velocity controller at limit

Explanation %1 = NC axis number
%2 = drive number
The velocity controller output has been at its limit for an impermissibly long pe-
riod (MD 5605: SPEEDCTRL_LIMIT_TIME (time for velocity controller at limit)).
Monitoring function is active only if the velocity setpoint is lower than
MD 5606: SPEEDCTRL_LIMIT_THRESHOLD (threshold for velocity controller
at limit).
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy
S Is the drive motor blocked?
S Is the encoder connected? (check encoder cable).
S Check shield on the encoder cable.
S Encoder defective?
S Check the encoder bar number.
S Replace closed-loop control module.
S Alter machine data MD 5605: SPEEDCTRL_LIMIT_TIME and MD 5606:
SPEEDCTRL_LIMIT_THRESHOLD to match the mechanical and dynamic
features of the axis.
To continue Cancel alarm in all channels of this mode group by pressing RESET key. Re-
program start the part program.

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6-196 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 6 Hydraulics Diagnostics

310 609 Axis %1, drive %2 encoder limit frequency exceeded

Explanation %1 = NC axis number
%2 = drive number
Actual velocity is exceeding encoder limit frequency fg,max = 650 kHz.
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy
S Incorrect encoder connected?
S Does setting in MD 5005: ENC_RESOL_MOTOR (no. of encoder marks
motor meas. system) match the encoder bar number?
S Is the encoder cable connected correctly?
S Is the shield of the encoder cable bonded over a large area?
S Replace the encoder.
S Replace the 611D hydraulics module.

To continue Cancel alarm in all channels of this mode group by pressing RESET key. Re-
program start the part program.

310 610 Axis %1, drive %2 incorrect piston position

Explanation %1 = NC axis number
%2 = drive number
The error is activated in response to a negative actual position of the drive.
Cause: Incorrect counting direction of actual position value at drive end.
Piston zero has been incorrectly adjusted.
If the drive is referenced and the offset between piston zero (piston limit stop at
A end) and machine zero has been entered in MD 5040, then the piston posi-
tion in MD 5741 may display only positive values (between zero and max. pis-
ton stroke).
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Correct counting direction of actual position value at drive end if:
1. Pos. setpoint voltage (e.g. function generator) Cylinder piston moves from
A to B
If not: Invert control signal (change MD 5476 bit 0)
2. Cylinder piston moves from A to B v_act (MD 5707) > 0
If not: Invert actual value (change MD 5011 bit 0)
3. Check piston zero adjustment and correct if necessary:
Set MD 5012 bits 14 and 15 to zero, save boot file, perform NCK Reset fol-
lowed by reference point approach and then adjust the piston position.
To continue Cancel alarm in all channels of this mode group by pressing RESET key. Re-
program start the part program.

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6 Hydraulics Diagnostics 08.99
02.99

310 611 Axis %1, drive %2 pressure sensor has failed

Explanation %1 = NC axis number
%2 = drive number
Force limitation or friction compensation is activated: MD 5241: Bit 0 or bit 1 is
set and both actual pressures are less than 2 % of the system pressure in MD
5101: WORKING_PRESSURE when the power is enabled.
Cause: Defect in pressure sensor or connecting lead.
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Check connections of the two pressure sensors.
If pressure sensors are not installed:

S Deactivate force limitation: MD 5241: Reset bit 0

S Deactivate friction compensation: MD 5241: Reset bit 1
To continue Cancel alarm in all channels of this mode group by pressing RESET key. Re-
program start the part program.

310 612 Axis %1, drive %2 force limitation off

Explanation %1 = NC axis number
%2 = drive number
The force limiting function is deactivated.
Cause: The force limiting function is deactivated even though

S the NC is specifying a force limit or

S “Travel to fixed stop” is selected.
Reaction Mode group not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Switch on force limitation: MD 5241: Set bit 0
To continue Cancel alarm in all channels of this mode group by pressing RESET key. Re-
program start the part program.

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6-198 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 6 Hydraulics Diagnostics

310 701 Axis %1, drive %2 invalid velocity controller cycle

Explanation %1 = NC axis number
%2 = drive number
An impermissible value has been set in the drive MD for the velocity controller
clock cycle MD 5001: SPEEDCTRL_CYCLE_TIME.
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Permissible: 62.5 µs
T
500 µs
To continue Switch control system OFF and ON again.
program

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 clock time: 250 µs
2. Maximum clock time: 4 s
3. Position controller clock cycle must be a multiple of the velocity controller
clock cycle in drive MD 5001: SPEEDCTRL_CYCLE_TIME.
Response NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Change the position controller clock cycle on the NC
To continue Switch control system OFF and ON again.
program

310 703 Axis %1, drive %2 invalid monitoring cycle

Explanation %1 = NC axis number
%2 = drive number
Monitoring cycle MD 5002: MONITOR_CYCLE_TIME (monitoring cycle) is in-
valid.

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6 Hydraulics Diagnostics 02.99

Reaction NC not ready

Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy See drive functions “FB / DB1”
MD1002
To continue Switch control system OFF and ON again.
program

310 704 Axis %1, drive %2 velocity controller clock cycle axially unequal
Explanation %1 = NC axis number
%2 = drive number
On 2-axis modules, the velocity controller clock cycle set in MD 5001:
SPEEDCTRL_CYCLE_TIME must be identical for both axes.
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Set velocity controller clock cycle in MD 5001: SPEEDCTRL_CYCLE_TIME to
an identical value for both axes.
To continue Switch control system OFF and ON again.
program

310 705 Axis %1, drive %2 monitoring cycle axially unequal

Explanation %1 = NC axis number
%2 = drive number
On 2-axis modules, the monitoring cycle set in MD 5002:
MONITOR_CYCLE_TIME (monitoring cycle) must be identical for both axes.
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Set MD 5002: MONITOR_CYCLE_TIME (monitoring cycle) to an identical value
for both axes.
To continue Switch control system OFF and ON again.
program

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02.99 6 Hydraulics Diagnostics

310 706 Axis %1, drive %2 maximum useful velocity invalid

Explanation %1 = NC axis number
%2 = drive number
The high maximum velocity setting in drive MD 5401: DRIVE_MAX_SPEED and
the velocity controller clock cycle in
MD 5001: SPEEDCTRL_CYCLE_TIME may cause a format overflow.
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Reduce maximum useful velocity setting in MD 5401: DRIVE_MAX_SPEED or
set a shorter velocity controller clock cycle in MD 5001:
SPEEDCTRL_CYCLE_TIME.
To continue Switch control system OFF and ON again.
program

310 707 Axis %1, drive %2 STS configuration axially unequal

Explanation %1 = NC axis number
%2 = drive number
On 2 axis modules, the configuration of the drive circuit MD 5003: STS_CON-
FIG (STS configuration) must be set to an identical value for both axes.
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Check drive MD 5003: STS_CONFIG (STS configuration) and set the bits for
the two axes on the module identically. (Do not change the default setting – it
represents the optimum configuration).
To continue Switch control system OFF and ON again.
program

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 (bar number) for the motor measuring system set
in MD 5005:
ENC_RESOL_MOTOR (no. of encoder marks motor measuring system) is ei-
ther zero or higher than the maximum input limit.

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6 Hydraulics Diagnostics 02.99

Reaction NC not ready

Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Match the number of encoder marks for the motor measuring system set in MD
5005:
ENC_RESOL_MOTOR (no. of encoder marks motor measuring system) to the
bar number of the connected encoder. (Default setting for motor measuring sys-
tem: 2 048 incr./rev).
To continue Switch control system OFF and ON again.
program

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 set in drive MD 5131:
CYLINDER_PISTON_DIAMETER is less than zero
or
the piston rod diameter set in drive MD 5132:
CYLINDER_PISTON_ROD_A_DIAMETER is greater than the piston 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
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a valid piston diameter setting in drive MD 5131:
Enter CYLINDER_PISTON_DIAMETER (0  D
500 mm).
or
set the piston rod diameter in drive MD 5132:
CYLINDER_PISTON_ROD_A_DIAMETER to a lower value than the piston di-
ameter in drive MD 5131: CYLINDER_PISTON_DIAMETER.
or
set the piston rod diameter in drive MD 5133:
CYLINDER_PISTON_ROD_B_DIAMETER to a lower value than the piston di-
ameter in drive MD 5131: CYLINDER_PISTON_DIAMETER.
To continue Switch control system OFF and ON again.
program

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6-202 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
08.99
02.99 6 Hydraulics Diagnostics

310 710 Axis %1, drive %2 distance-coded scale is incorrectly parameterized

Explanation %1 = NC axis number
%2 = drive number
When a distance-coded scale (MD 5011 bit 7=1) is selected, a linear measuring
system must also be configured (MD 5011 bit 4=1).
Reaction NC not ready
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
Alarm is displayed.
Interface signals are set.
Remedy Check MD 5011: ACTUAL_VALUE_CONFIG (configuration of actual-value
sensing) and configure if necessary.
To continue Switch control system OFF and ON again.
program

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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy
S Increase the velocity controller cycle in MD 5001:
SPEEDCTRL_CYCLE_TIME.
S Reduce the feedforward control factor of the force controller in MD 5247:
FORCE_FFW_WEIGHT.
S Increase the controlled system gain setting in MD 5435: CON-
TROLLED_SYSTEM_GAIN.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
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:

S MD 5406: SPEEDCTRL_GAIN_A (gain at cylinder edge A end)

or
S MD 5407: SPEEDCTRL_GAIN (gain for piston position with lowest natural
frequency)
or
S MD 5408: SPEEDCTRL_GAIN_B (gain at cylinder edge B end)

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6 Hydraulics Diagnostics 02.99

Reaction NC not ready

Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a lower value for the P gain of the velocity controller:

S MD 5406: SPEEDCTRL_GAIN_A (gain at cylinder edge A end)

or

S MD 5407: SPEEDCTRL_GAIN (gain for piston position with lowest natural

frequency)
or

S MD 5408: SPEEDCTRL_GAIN_B (gain at cylinder edge B end)

To continue Cancel alarm in all channels with RESET key. Restart the part program.
program

310 752 Axis %1, drive %2 I-action gain of velocity controller invalid
Explanation %1 = NC axis number
%2 = drive number
The I-action gain set in MD 5409: SPEEDCTRL_INTEGRATOR_TIME is not
representable.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

310 753 Axis %1, drive %2 D component of velocity controller invalid

Explanation %1 = NC axis number
%2 = drive number
The D component of the velocity controller is too high:

S MD 5431: SPEEDCTRL_DIFF_TIME_A (gain at cylinder edge A end)

or

S MD 5432: SPEEDCTRL_DIFF_TIME (gain for piston position with lowest

natural frequency) or

S MD 5433: SPEEDCTRL_DIFF_TIME_B (gain at cylinder edge B end)

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02.99 6 Hydraulics Diagnostics

Reaction NC not ready

Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a lower value for the D component of the velocity controller:

S MD 5431: SPEEDCTRL_DIFF_TIME_A (gain at cylinder edge A end)

or

S MD 5432: SPEEDCTRL_DIFF_TIME (gain for piston position with lowest

natural frequency) or

S MD 5433: SPEEDCTRL_DIFF_TIME_B (gain at cylinder edge B end)

To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

310 754 Axis %1, drive %2 friction compensation gradient too high
Explanation %1 = NC axis number
%2 = drive number
The friction compensation gradient set in MD 5460: FRICTION_COMP_GRADI-
ENT is too high.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Reduce the gradient of the friction compensation in MD 5460: FRIC-
TION_COMP_GRADIENT.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

310 755 Axis %1, drive %2 area adaptation too high

Explanation %1 = NC axis number
%2 = drive number

S The positive area adaptation factor set in drive MD 5462:

AREA_FACTOR_POS_OUTPUT is too high or

S the negative area adaptation factor set in drive MD 5463:

AREA_FACTOR_NEG_OUTPUT is too high.

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 6-205
6 Hydraulics Diagnostics 02.99

Reaction NC not ready

Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy
S Select a lower setting for the positive area adaptation factor in MD 5462
AREA_FACTOR_POS_OUTPUT or

S select a lower setting for the negative area adaptation factor in MD 5463
AREA_FACTOR_NEG_OUTPUT.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a valid controlled system gain setting in drive MD 5435:
CONTROLLED_SYSTEM_GAIN (see drive model data calculation).
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.

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08.99
02.99 6 Hydraulics Diagnostics

Remedy The blocking frequency in

S drive MD 5514: SPEED_FILTER_1_SUPPR_FREQ or

S drive MD 5210: OUTPUT_VCTRL_FIL_1_SUP_FREQ or
S drive MD 5213: OUTPUT_VCTRL_FIL_2_SUP_FREQ or
S drive MD 5268: FFW_FCTRL_FIL_1_SUP_FREQ or
S drive MD 5288: OUTPUT_FIL_1_SUP_FREQ
must be lower than the reciprocal of two velocity controller clock cycles in
MD 5001: SPEEDCTRL_CYCLE_TIME, i.e. less than
1/(2*MD 5001*31.25 microsec).
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The natural frequency in Hz of a velocity must be less than the reciprocal of two
velocity controller clock cycles.
Velocity filter:
MD 5520 * 0.01 * MD 5514 < 1 / ( 2 * MD 5001 * 31.25 microsec)

S BSF natural frequency MD 5520: SPEED_FILTER_1_BS_FREQ

S BSF blocking frequency MD 5514: SPEED_FILTER_1_SUPPR_FREQ
S Velocity controller clock cycle MD 5001: SPEEDCTRL_CYCLE_TIME
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 6-207
6 Hydraulics Diagnostics 08.99
02.99

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 Velocity 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
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The numerator bandwidth must be less than twice the blocking frequency.

S Velocity filter 1:
– BSF bandwidth numerator drive MD 5516:
SPEED_FILTER_1_BW_NUMERATOR
– BSF blocking frequency drive MD 5514:
SPEED_FILTER_1_SUPPR_FREQ
MD 5516
2 * MD 5514

S Control output filter 1 in velocity controller:

– BSF numerator bandwidth drive MD 5212:
OUTPUT_VCTRL_FIL_1_BW_NUM
– BSF blocking frequency drive MD 5210:
OUTPUT_VCTRL_FIL_1_SUP_FREQ
MD 5212
2 * MD 5210

S Control output filter 2 in velocity controller:

– BSF numerator bandwidth drive MD 5215:
OUTPUT_VCTRL_FIL_2_BW_NUM
– BSF blocking frequency drive MD 5213:
OUTPUT_VCTRL_FIL_2_SUP_FREQ
MD 5215
2 * MD 5213
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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6-208 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
08.99
02.99 6 Hydraulics Diagnostics

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 fre-
quency.
The error message is only generated for the general bandstop if the following
applies:
Velocity filter 1:
MD 5516 > 0.0 or
MD 5520 <> 100.0
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The denominator bandwidth of a velocity filter must be smaller than twice the
natural frequency.
Velocity filter 1:

S BSF bandwidth drive MD 5515: SPEED_FILTER_1_BANDWIDTH

S BSF blocking frequency drive MD 5514:
SPEED_FILTER_1_SUPPR_FREQ

S BSF natural frequency drive MD 5520: SPEED_FILTER_1_BS_FREQ

MD 5515
2 * MD 5514 * 0.01 * MD 5520
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a lower value for the force controller P gain in MD 5242:
FORCECTRL_GAING.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 6-209
6 Hydraulics Diagnostics 02.99

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 is not
representable.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

310 763 Axis %1, drive %2 D component of force controller invalid

Explanation %1 = NC axis number
%2 = drive number
The D component of the force controller in MD 5246: FORCECTRL_DIFF_TIME
is too high.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a lower value for the force controller D component in MD 5246:
FORCECTRL_DIFF_TIME.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy Enter a valid controlled-system gain setting in drive MD 5240
FORCECONTROLLED_SYSTEM_GAIN (see Calculate Model Data).
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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6-210 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
08.99
02.99 6 Hydraulics Diagnostics

310 771 Axis %1, drive %2 gradient in fine range of valve characteristic is less than
zero
Explanation %1 = NC axis number
%2 = drive number
The gradient in the fine range of the valve characteristic is less than zero.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The gradient in the fine range is calculated according to the:

S positive quadrant: (MD 5464–MD 5480)/(MD 5465–MD 5481)

S negative quadrant: (MD 5467–MD 5483)/(MD 5468–MD 5484)

Enter a valid combination in the above drive MD.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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 range of the valve characteristic is less than zero.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The gradient in the coarse range is calculated according to the:

S positive quadrant: (MD 5485–MD 5464)/(MD 5486–MD 5465)

S negative quadrant: (MD 5487–MD 5467)/(MD 5488–MD 5468)

Enter a valid combination in the above drive MD.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 6-211
6 Hydraulics Diagnostics 08.99
02.99

310 773 Axis %1, drive %2 gradient at end of saturaton 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 cannot therefore be
inverted.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The gradient at the end of the saturation region is calculated according to the:

S positive quadrant: 2(1.0–MD 5485)/(1.0–MD 5486)

–(MD 5485–MD 5464)/(MD 5486–MD 5465)

S negative quadrant: 2(1.0–MD 5487)/(1.0–MD 5488)

–(MD 5487–MD 5467)/(MD 5488–MD 5468)
Enter a valid combination in the above drive MD.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The zero and breakpoint ranges overlap if:

S positive quadrant: (MD 5481+MD 5482)>(MD 5465–MD 5466)

S negative quadrant: (MD 5484+MD 5482)>(MD 5468–MD 5466)

Enter a valid combination in the above drive MD.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program

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08.99
02.99 6 Hydraulics Diagnostics

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.
Reaction NC not ready
Switchover for entire channel via MD might be possible.
Channel not ready.
NC Stop in response to alarm.
NC Start disable.
The NC switches to follow-up mode.
Alarm is displayed.
Interface signals are set.
Remedy The breakpoint range and saturation region overlap if:

S positive quadrant: (MD 5465+MD 5466)>MD 5486

S negative quadrant: (MD 5468+MD 5466)>MD 5488

Enter a valid combination in the above drive MD.
To continue Cancel alarm in all channels by pressing RESET key. Restart the part program.
program
J

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 6-213
6 Hydraulics Diagnostics 08.99
02.99

Notes

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6-214 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Peripherals/Accessories 7
7.1 Measuring systems

7.1.1 Encoders, linear scales

Note
For connector assignments, see Section 5.1.1.

Encoder The HLA module is designed to evaluate

specification S incremental measuring system with sinusoidal signals (A, B) and a refer-
ence signal (R)
or
S absolute measuring system with sinusoidal signals (A, B) and EnDat inter-
face for absolute position sensing
with the following signal limit data:

Signal
volt-
ages

Track signal A
UM(A)
Track signal *A

0 Mech. angle ϕ
Differential signal (A – *A)
Signal
volt-
ages

Track signal B
UM(B) Track signal *B

0 Mech. angle ϕ

Differential signal (B – *B)

Signal
volt-
ages

UM(R) Track signal R

Differential signal (R – *R) Track signal *R

0 Mech. angle ϕ

Fig. 7-1 Required waveform of measuring system signals for data definition

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 7-215
7 Peripherals/Accessories 02.99
7.1 Measuring systems

Differential signal (B – *B) Differential signal (A – *A)

360 degrees Electrical
Direct component UG(A)

0 Mech. angle ϕ

45 degrees

Direct component UG(B)

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 waveform of motor system signals (incremental and reference sig-
nals) after differential amplification for data function

Table 7-1 Limit data of measuring system signals

Parameter Designation Min. Typ. Max. Unit

Mean voltage UM(A); UM(B); UM(R) 1.75 3.25 V
Amplitude A – *A; B – *B 350 500 600 mv
Ratio (A – *A)/(B – *B) 0.9 1.0 1.1 –
Dynamic change in amplitude ∆(A – *A)/360° el.; ∆(B – *B)/360° el. – – 0.3 mV/360° el.
Direct component UG(A)/amplitude (A – *A); –0.2 0 +0.2
UG(B)/amplitude (B – *B);
Dynamic change in ∆UG(A)/360° el.; – – 1 mV/360° el.
direct component ∆UG(B)/360° el.
Signal frequency fs – – 200 KHz
Phase displacement β 85 90 95 Degrees
Harmonic distortion1) k – – 1 %
Useful signal R – *R 300 – 1500 mV
DC voltage UG(R) –150 – –500 mV
Uniqueness range α1; α2 50 – 270 Degrees

 U12+U22+...Un2
1) Definition for harmonic distortion: k = U0: Fundamental component
 U02+U12+...Un2 U1...Un: Harmonic components

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02.99 7 Peripherals/Accessories
7.1 Measuring systems

Note
If signals which do not conform to this specification are used, problems such as
speed ripple, positioning inaccuracy or other malfunctions may be encoun-
tered.

Options When the encoder is parameterized, one of the options “Incremental” or “Abso-
lute” (EnDat interface) must be selected in menu display “Measuring system
data for HLA”.
The purpose of these options is to set the following drive machine data:

S MD 5011: ACTUAL_VALUE_CONFIG (actual-value sensing configuration)

S MD 5024: DIVISION_LIN_SCALE (linear scale graduations).

Table 7-2 MD 5011 assignments

Bit No. Meaning

Bit 0 1 = track inversion ON
Bit 1 1 = phase error compensation active
Bit 2 Not assigned
Bit 3 1 = absolute encoder (EnDat interface)
Bit 4 1 = linear measuring system
Bit 5 Reserved
Bit 6 Reserved
Bit 7 1 = distance-coded measuring system
Bit 8 1 = zero marker selection by NC (several zero markers)
Bits 9–11 Not assigned
Bit 12 Reserved
Bit 13 Reserved
Bits EnDat data transfer rate
14/15

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7 Peripherals/Accessories 02.99
7.1 Measuring systems

7.1.2 Connection diagrams

Connection
options

Hydraulics 6FX2002 – 2CA11 – 1JJJ v 40 m

module Incremental en-
(HLA) coder 1 Vpp

Direct linear in-

X101/X102 cremental mea-
Adapter cable1) suring system
310 128 LS 186

310 123 LS 486

6FX2002 – 2AD00 – 1JJJ v 40 m

Linear
absolute
Adapter cable1) measuring system
313 791 (EnDat)
LC 181

Fig. 7-3 Example showing connection options for measuring system cable

1) Cable can be ordered from supplier of linear scale.

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02.99 7 Peripherals/Accessories
7.1 Measuring systems

Pin 1 Cable print (order no., length in m, manufacturer,

month/year of manufacture)

Z 2:1
Length according to length code

Z 8 9 1
7 12 10 2
6 11 3
5 4

2
3

1 3

A 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 og
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

HLA module Measuring system

Item Meaning

1 Sub D female connector, 15-pin, with screw lock

6FC9348-7HX
2 Signal lead 4x2x0.38+4x0.5
6FX2008-1BD21
3 12-pin connector
6FX2003-0CE12

Order No. (MLFB) of measuring system lead: 6FX2002-2CA11-1VVV

Fig. 7-4 Measuring system lead for encoder with voltage signals (X101/X102)

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7 Peripherals/Accessories 02.99
7.1 Measuring systems

Pin 1 Cable print (order no., length in m, manufacturer,

month/year of manufacture)

Z 2:1
Length according to length code
Z 1 11 10
2 13 1216 9
17
3 14 15
8
4 7
5 6

2
3

1 3

A 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

5 Data 0.14 vt Data

14
8 *data 0.14 bu *data
17
13 11
1) Clock cycle 0.14 gy Clock cycle 1)
14 8
*clock cycle 0.14 bu *clock cycle
15 9
P encoder 0.5 rd P encoder
1 7
5V sense 0.14 ye 5V sense
9 1
M encoder 0.5 bk M encoder
2 10
0V sense 0.14 wh-bk 0V sense
11 4
Housing Housing

HLA module 1) Single screens bundled, connected to contact Measuring system

via largest possible cross-sectional area.

Item Meaning

1 Sub D female connector, 15-pin, with screw lock

6FC9348-7HX
2 Signal lead 3x2x0.14+4x0.14+2x0.5
6FX2008-1BD41
3 17-pin connector
6FX2003-0CE17

Order No. (MLFB) of lead: 6FX2002-2AD00-1VVV

Fig. 7-5 Measuring system lead for encoder with voltage signals + EnDat (X101/X102)

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7-220 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
02.99 7 Peripherals/Accessories
7.2 BERO (X432)

7.2 BERO (X432)

Only BEROs of type 3-wire PNP NO contact may be used.
We recommend the following BERO models:
SIEMENS BERO M30 3RG 4014-0AG01
BERO M12 3RG 4012-3AG01

Note
The BERO cable must be shielded.

Table 7-3 Pin assignment X432

Terminal name Type1) Signal name

B1/B2 E BERO (external refrence system) axis 1/2
19 A Power supply for BERO ground external
9 A Power supply for BERO 24 V external

1) E: Input, A: Output

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7 Peripherals/Accessories 02.99
7.3 Pressure sensing

7.3 Pressure sensing

7.3.1 Sensors

Note
For connector assignments, see Section 5.1.2.

General The task of pressure sensors is to convert mechanical quantity “pressure” into
Electrical quantity “voltage” or “current”.
The pressure sensors included in the Bosch hydraulic product range are suit-
able for pressure monitoring and control applications in machine construction,
on injection moulding machines, presses and many other areas.
The most important features of the sensors are

S pressure sensor element consisting of high-quality steel membrane (spring

material), coated with thin-layer strain gauges in full-bridge connection

S integrated electronic circuitry with temperature compensation

S signal output proportional to pressure
S zero point and sensitivity are calibrated exactly by manufacturer

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.

S The sensor must be installed in the hydraulic system in such a way as to

prevent any air cushions from developing between the sensor membrane
and the pressure medium.

S Pressure medium: Hydraulic fluid; other fluids only after consultation with
Bosch.

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)

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02.99 7 Peripherals/Accessories
7.3 Pressure sensing

Table 7-4 Recommended types of pressure sensor

Signal Pressure range Connector Bosch order no.

0...10 V 100 bar Rectangular connector, 0811 405 554
4 i
4-pin
210 bar 0811 405 540
350 bar 0811 405 547
210 bar 7-pin circular connector 0811 405 531
350 bar 0811 405 532

Dimensions/
terminal
assignments

73–1
G1/4”ISO 228 A

32
0.3 – 0.4 Nm
MA=20+5 Nm
O 18.8

12
BOSCH

O 35

12
6.5

13x2 15 47–1 22.5

Conduit thread 7

4
2 3 Ref. 0 V (signal)
3
P Usig
2
U 0V
4 1 1
Supply

Fig. 7-6 Pressure sensors, order nos. 0811 405 540, 0811 405 547 and 0811 405 554

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7 Peripherals/Accessories 02.99
7.3 Pressure sensing

G1/4”ISO 228 A
32
MA=20+5 Nm

O 18.8
12

BOSCH

O 34
12

13x2 15 43–1

1
Supply
2
P 0V
3
U Usig
4
Ref. 0 V (signal)
5
6
7

Fig. 7-7 Pressure sensors, Order Nos. 0811 405 531 and 0811 405 532

7P

Bosch Order No. 1

834 484 141

IP 40

Fig. 7-8 Accessories for pressure sensors Order Nos. 0811 405 531 and 0811 405 532

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02.99 7 Peripherals/Accessories
7.3 Pressure sensing

Characteristics
Table 7-5 Characteristics of pressure sensors

Characteristic Value range

Signal voltage 0...10 V
Supply voltage
0811 405 510/0811 405 510 13...28 V DC
0811 405 510/0811 405 511 13...28 V DC
0811 405 523/0811 405 523 12...28 V DC
0811 405 523/0811 405 530 12...28 V DC
0811 405 523/0811 405 554 12...28 V DC
“Dynamic” overload capability 2 x pnom (up to 20 x 106 load cycle)
“Static” overload capability 3 x pnom (up to 10 x 0.5 sec each)
Burst pressure >1500 bar
Linearity deviation incl. hysteresis <0.5 %
Zero point dispersion <0.5 %
Sensitivity dispersion <0.5 %
Temp. coefficient of zero point <0.2 %/10 °C
Temp. coefficient of sensitivity <0.25 %/10 °C
Measurement temperature range (compen- +10 to +70 °C
sated) –10 to +80°C
Operating temperature range –30 to +90°C
Storage temperature range
Hydr. dead volume Approx. 0.3 cm3
Measuring frequency (–3 dB)
1 kHz
Natural frequency 10 kHz
Max. acceleration
25 g (g=9.81 ms2)
Connecting piece material (hydr.) St 37  2 K DIN 1652 (chemically nickeled)
Membrane material X 5 CrNiCuNb 1744
Hydraulic connection G 1/4 (ISO 228)

Accessories For pressure sensors with order no.: 0811 405 523
0811 405 530
0811 405 554,
the 4-pin cube-shaped connector is supplied. Replacement connectors can be
ordered under no.: 1834 484 061 from Bosch.

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7 Peripherals/Accessories 02.99
7.3 Pressure sensing

7.3.2 Connection diagrams

Note
The following cable data for hydraulics equipment apply for Bosch products. If
hydraulics components supplied by other manufacturers are used, the pin as-
signments of the hydraulic-end connections might be different!

Cable print (order no., length in m, manufacturer,

month/year of manufacture)

Length according to length code

Pin 1 Note: Max. approved system cable length 40 m

2 3

1
3
A
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 og 3
PIST1AN 0.18 Actual value, ground
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 3
PIST1BN 0.18 og Actual value, ground
11 4
Shield
Housing 1)

HLA module Pressure sensor A or B

1) Shield insulated

Item Meaning

1 Sub D male connector, 15-pin, with screw lock UNC 4-40

6FC9341-1HC

2 Signal lead 2x(2x0.18) C

6FX2008-1BD71

3 4-pin or 7-pin female connector

Order number as stated in Table 7-4, e.g. Bosch 1834484061
(connector included with pressure sensor).

Order No. (MLFB) of signal lead for pressure sensors: 6FX2002-2AD00-1VVV

Fig. 7-9 Signal lead for pressure sensors (X111/X112)

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02.99 7 Peripherals/Accessories
7.4 Connection diagrams for servo solenoid valves

7.4 Connection diagrams for servo solenoid valves

Note
The following cable data for hydraulics equipment apply specifically to Bosch
servo solenoid valves (directly and pilot actuated).

Cable print (order no., length in m, manufacturer,

month/year of manufacture)

Pin 1 Z 2:1
Length according to length code
Note: Max. approved system cable length 40 m
Z
A
B F

C E
D

2 3

1
3

7 USOLL1P 0.38 bk Setpoint output +/– 10 V D

USOLL1N 0.38 bn Setpoint output, ground
6 E
UIST1P 0.38 rd Actual value input +/–10 V
15 F
UIST1N 0.38 og Actual value input, ground
14 0.38 bu C
0.38 vt
0.38 ye
0.38 gn
P24RV1 0.5 wh-rd +24 V switched
4 A
P24RV1 0.5 wh-ye +24 V switched
3
M24EXT 0.5 wh-bk External 24 V ground
10 M24EXT 0.5 wh-bu External 24 V ground B
9 Shield
Housing

HLA module Servo solenoid valve

Item Meaning

1 Sub D male connector, 15-pin, with screw lock UNC 4-40

6FC9341-1HC
2 Signal lead 4x(2x0.38) + 4x0.5 C
6FX2008-1BD21
3 7-pin female connector
GE.570102.0144.00

Order No. (MLFB) of signal lead for 7-pin servo solenoid valve: 6FX2002-2BA00-1VVV

Fig. 7-10 7-pin signal lead for servo solenoid valve (X121/X122) – standard version

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7 Peripherals/Accessories 02.99
7.4 Connection diagrams for servo solenoid valves

Note
The pin assignments on valves supplied by other manufacturers may deviate
from the assignments shown in Fig. 7-10. Cables must be assembled by the
customer!

Cable print (order no., length in m, manufacturer,

month/year of manufacture)

Pin 1 Z 2:1
Length according to length code
Note: Max. approved system cable length 40 m
Z
A
B F

C E
D

2 3

1
3

7 USOLL1P 0.38 bk Setpoint output +/– 10 V D

USOLL1N 0.38 bn Setpoint output, ground
6 E
UIST1P 0.38 rd Actual value input +/–10 V
15 F
UIST1N 0.38 og Actual value input, ground
14 0.38 bu C
1
0.38 vt
0.38 ye
0.38 gn
2
P24RV1 0.5 wh-rd +24 V switched
4 A
P24RV1 0.5 wh-ye +24 V switched
3
M24EXT 0.5 wh-bk External 24 V ground
10 M24EXT 0.5 wh-bu External 24 V ground B
9 Shield
Housing

HLA module Servo solenoid valve

Item Meaning

1 Sub D male connector, 15-pin, with screw lock UNC 4-40

6FC9341-1HC
2 Signal lead 4x(2x0.38) + 4x0.5 C
6FX2008-1BD21
3 7-pin female connector
Valve-specific

Fig. 7-11 Interconnection diagram for 7-pin servo solenoid valve (X121/X122) – connection option 2 (customized)

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02.99 7 Peripherals/Accessories
7.4 Connection diagrams for servo solenoid valves

Note
The following cable data for hydraulics equipment apply specifically to Bosch
HRVs (directly and pilot actuated).

Cable print (order no., length in m, manufacturer,

month/year of manufacture)

Pin 1 Length according to length code Z 2:1

Note: Max. approved system cable length 40 m
Z 5
6 4
10 3
7 11 9
2
8 1

2 3

1
3

7 USOLL1P 0.38 bk Setpoint output +/– 10 V 4

USOLL1N 0.38 bn Setpoint output, ground
6 5
UIST1P 0.38 rd Actual value input +/–10 V
15 6
UIST1N 0.38 og Actual value input, ground
14 7
P24RV1 0.38 bu +24 V switched
2 3
P24RV1 0.38 vt +24 V switched
1 9
M24EXT 0.38 ye External 24 V ground
9 10
0.38 gn
P24RV1 0.5 wh-rd +24 V switched
4 1
P24RV1 0.5 wh-ye +24 V switched
3
M24EXT 0.5 wh-bk External 24 V ground
11 M24EXT 0.5 wh-bu External 24 V ground 2
10
Shield
Housing

HLA module Servo solenoid valve

Item Meaning

1 Sub D male connector, 15-pin, with screw lock UNC 4-40

6FC9341-1HC
2 Signal lead 4x(2x0.38) + 4x0.5 C
6FX2008-1BD21
3 12-pin female connector
GE.570102.0145.00

Order No. (MLFB) of signal lead for 12-pin servo solenoid valve: 6FX2002-2BA10-1VVV

Fig. 7-12 12-pin signal lead for servo solenoid valve (X121/X122)

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 7-229
7 Peripherals/Accessories 02.99
7.4 Connection diagrams for servo solenoid valves

Note
The following data for the connectors on the servo solenoid valve signal lead
are required only for spare parts orders or pre-assembly of cables by the cus-
tomer. The cables are normally supplied fully pre-assembled by Siemens.

A
B F

C E
D

10 2.6
28.6 66

Metal Crimp connection 0.08 Bosch1 834 482 023

Plastic Crimp connection 0.05 Bosch1 834 482 026

Plastic Soldered 0.05 Bosch1 834 482 022

connection HirschmannCM 06 EA 14S-61S
Version Contacts kg Order No.

3 7 4
2
1 6

21.5 Approx. 66

Plastic Soldered 0.05 Bosch1 834 484 140

connection Binder723-2-09-0126-25-07
Version Contacts kg Order No.

Fig. 7-13 Dimension diagram of circular, 7-pin connector

5 4
6
10 3
7 11 9
2
8 1

29 79

Plastic Crimp connection 0.05 Bosch1 834 484 142

HirschmannNIIR EF K B0

Version Contacts kg Order No.

Fig. 7-14 Dimension diagram of circular, 12-pin connector

J

 Siemens AG 2000. All rights reserved

7-230 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Service 8
8.1 Areas of responsibility of Siemens and Bosch
The areas of responsibility with respect to Sales and Servicing as shown in
Table 8-1 below have been agreed between Siemens and Bosch.

Table 8-1 Areas of responsibility for sales and servicing

Siemens AG Robert Bosch GmbH

“Electrical” equipment/ “Hydraulic” equipment/
configuring configuring
HMI/MMC Valves
NC/PLC Hydraulic equipment
NE (mains supply equipment) Power units
Closed-loop control modules Cylinders
Power sections Pipework
Motors Pressure sensors
Cabling Encoder sensors
Hydraulic drive module
Hydr. system cabling (see Sect. 7.3.2)

Note
Neither company bears sole responsibility for the overall installation.
Siemens AG and Robert Bosch GmbH are deemed to bear responsibility only if
they are the system supplier of the components listed in Table 8-1 or have certi-
fied explicit system compatibility for components supplied by other manufactur-
ers.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition 8-231
8 Service 02.99
8.2 Hotline

8.2 Hotline

Siemens AG Hotline
Tel. No. ++49–(0)9131/98–3471 (FDD) and –3475 (MSD)
Fax. ++49–(0)9131/98–1313
Mon–Fri 8.00 am – 5.00 pm
Emergency service
Tel. No. 0172 840 8776
Mon–Fri 5.00 – 10.00 pm
Sat 8.00 am – 10.00 pm
Christmas Eve 8.00 am – 2.00 pm
New Year’s Eve 8.00 am – 2.00 pm
Sun None

Robert Bosch Hotline

GmbH
Tel. No. ++49–(0)711/811–24806
Fax. ++49–(0)711/811–1424
Mr. Laube AT/VKS2–Si
Mail [email protected]
Mon–Fri 7.30 am – 5.00 pm

 Siemens AG 2000. All rights reserved

8-232 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Hydraulics A
A.1 Servo solenoid valves

A.1.1 General

The servo solenoid valve is the final control element in the electro-hydraulic
control loop. It converts electrical quantity U=–10...+10 V into hydraulic quanti-
ties pressure p and flow Q, and thus into a cylinder movement.

Spool principle These valves are of the sliding-spool type. A valve spool with 4 control edges
moves inside a steel sleeve on which the control bore is connected to the 4
ports in the valve housing.
The ports in the valve housing are:

S P: Pressure port (inlet)

S T: Tank port (return)

S A and B: Working ports (cylinder)

The valve spool slides steplessly through 3 switching positions (continuous
valve).

A B

ÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎ Housing

ÎÎÎÎÎ ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎ Steel sleeve

ÎÎÎ
ÎÎÎÎÎÎÎÎÎ ÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎ
Valve spool

ÎÎÎÎÎÎÎ ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
T P

Fig. A-1 Sliding spool principle

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-233
A Hydraulics 02.99
A.1 Servo solenoid valves

Solenoid actuation On the standard servo solenoid valves of sizes 6 and 10, the valve
with position spool is actuated directly by a stepless actuating solenoid. This converts a cur-
control of valve rent I into a force F, which is compared with the force of the reset spring. This
spool comparison of forces finally produces a travel s, and thus an opening cross-sec-
tion on the control edges of the valve spool.
In order to compensate for disturbance forces acting on the valve spool (flow
forces) and to reduce the hysteresis and response sensitivity or range of inver-
sion, the position of the armature, and therefore the spool travel, is scanned and
applied to a position control loop as an actual value. Deviations from the spool
position setpoint are correctly continuously in this way. This method is particu-
larly successful in reducing the valve sensitivity to dirt.
Very small control deviations, such as those caused when the valve spool
“sticks”, can be corrected through mobilization of the total available magnetic
force.
A wear-resistant, proximity-type differential transformer (LVDT) is employed as
the spool travel sensor.

Valve amplifier
UE

FF Valve spool FM

ÉÉ
ÉÉ U

ÉÉ
S

Reset spring Actuating Position

solenoid sensor
F

FF

FM

Fig. A-2 Solenoid actuation with position control of valve spool

Graphic 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
squares denoting the valve positions.
The three stepless-transition valve positions are represented by additional lines.
The symbol also indicates the relevant mode of actuation, in the example below,
direct solenoid actuation with spring return at one end.
In the de-energized state, the valve assumes a 4th fail-safe position. Two alter-
native fail-safe positions are available.

 Siemens AG 2000. All rights reserved

A-234 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 A Hydraulics
A.1 Servo solenoid valves

The symbol also reveals the principle of position control applied to the valve
spool.

Reset spring Actuating solenoid

A B Position sensor

P T

Setpoint
Valve amplifier with UE=0...10V
position control

Fail-safe disabled Fail-safe enabled

A B A B

P T P T

Fig. A-3 Graphic symbol

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-235
A Hydraulics 02.99
A.1 Servo solenoid valves

Zero overlap in Zero overlap by a continuous valve around its mid-position is an important req-
mid-position uisite for its application in a position control loop.
A positive overlap has a disturbing effect because of the final control element
“dead zone”.
In contrast, a negative overlap results in a marked increase in oil leakage.
In order to achieve zero overlap, valve spools, spool housings and spool
sleeves must be manufactured with extreme precision and made of wear-resist-
ant materials. The production costs incurred are correspondingly high.
To maintain the zero overlap over prolonged operating periods, it is essential to
ensure that a clean pressure medium is used (to prevent erosion of control
edges).

+Q +Q +Q

–UE +UE –UE +UE –UE +UE

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ ÎÎÎ ÎÎÎ

ÎÎÎÎ
ÎÎÎ
–Q –Q –Q

ÎÎÎÎÎÎÎ ÎÎÎ ÎÎÎ ÎÎÎ

ÎÎÎ ÎÎÎ
ÎÎÎÎ
ÎÎÎ
A B A B A B

ÎÎÎÎ
ÎÎ ÎÎÎ
ÎÎÎ ÎÎÎ
ÎÎÎÎÎÎ ÎÎÎ
ÎÎ ÎÎÎ
ÎÎÎÎ ÎÎÎ
ÎÎÎÎ ÎÎÎ
Î ÎÎÎÎ
ÎÎÎ ÎÎÎ
ÎÎÎ
ÎÎ
ÎÎÎÎÎÎÎÎÎ
T ÎÎÎÎÎÎÎÎÎÎÎÎ
P
Ü=–
T T P
Ü=0
T ÎÎÎÎÎÎÎ
T ÎÎ P
Ü=+
T

Fig. A-4 Zero overlap in mid-position

Pressure The quality of zero overlap in the mid-position is represented by the so-called
intensification pressure intensification characteristic.
This states what percentage of the setpoint signal is needed to achieve a pres-
sure difference corresponding to 80 % system pressure at the closed load ports.
The values of this characteristic are typically in the 1...3 % range.
The following graphic representation of the measurement, which acquires all 4
control edges, provides precise information.

Dp
np [% of pPU]

PA PB 80
60
40
20
A B –UE[%] +UE [%]
3 2 1 1 2 3
20
40
P 60
PPU
80

Fig. A-5 Pressure amplification

 Siemens AG 2000. All rights reserved

A-236 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 A Hydraulics
A.1 Servo solenoid valves

Flow The stepless slide movement, and thus the change in the throttle cross-section
characteristic, at the control edges, results in a corresponding flow which is represented as a
linear function of spool travel s or of electrical input signal U (manipulated variable).
The linearity is determined by the geometry of the control edges of the spool
sleeve.
The flow is not only dependent on the opening cross-section, but also on the
pressure drop in accordance with the law of flow:

Q  pnp

auch vom Druckabfall abhängig.

Flow Q npNOM per control

edge = 35 bar

P A to
B T
npPA npBT
A B

P T

A B Spool travel s
Input signal I
P T

P B to
A T

Fig. A-6 Flow characteristic

Q
Window in spool sleeve

ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ UE

Spool stroke

Fig. A-7 Control edge on spool sleeve

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-237
A Hydraulics 02.99
A.1 Servo solenoid valves

Flow In addition to valves with a linear characteristic, values with a knee-shaped

characteristic, characteristic are used in many cases to increase the finer resolution in the
knee-shaped positioning range to better control the effects of static/sliding friction. These are
achieved by means of corresponding windows (control edges) in the steel valve
sleeve. A constant machining velocity of the drive directly at the knee-point of
the valve is not recommended.
Definition for the position of the knee-point, e.g. 40% knee.
Up to 40 % of the spool value or setpoint signal, only 10 % of the maximum
opening cross-section (flow) is released.

+Q

Rapid traverse

10%
–UE +UE
40%
Machining velocity

–Q

Fig. A-8 Definition of flow characteristic

ÎÎÎÎÎÎÎ
Q
10 % Q max

ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ 40 % UE UE

Spool stroke

Fig. A-9 Valve with knee-shaped characteristic

Linearization of The knee-shaped characteristic of the valve is linearized in the HLA module to
knee-shaped 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

Valve characteristic

Linearized characteristic
10%
–UE +UE
40%
Compensation

–Q

Fig. A-10 Linearization of knee-shaped characteristic

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A-238 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 A Hydraulics
A.1 Servo solenoid valves

Rated flowrate This describes the maximum flowrate with fully opened valve in relation to a
pressure drop of ∆p=35 bar per control edge.
Typical values are:
S Size 6: Q=4...40 l/min
S Size 10: Q=50...100 l/min
With pilot-controlled valves, the rated flowrate is related to ∆p=5 bar per control
edge. (Reduction in losses with higher flow rates.)
The values for sizes 10 and 16 are then as follows:
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

Asymmetrical The speed of the cylinder is determined by a combined throttling effect at the
characteristics inlet and outlet. The cylinder is clamped hydraulically at both ends.
In order to ensure adequate effectiveness of the outlet throttle on cylinders with
single-ended piston rod and draw load, larger servo solenoid valves with asym-
metrical characteristics are available as alternatives.

QA
+Q

PA
v

PB
–UE +UE
A B QB

P T
–Q

Fig. A-11 Asymmetrical characteristics

Dynamic response The dynamic response characteristics indicate how fast the valve can react to
setpoint changes.
One characteristic that is indicative of dynamic response is the actuating time.
This defines how much time the valve spool needs to open the valve in re-
sponse to a step change in the input signal from 0 V to 10 V.

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-239
A Hydraulics 02.99
A.1 Servo solenoid valves

More exact information about the dynamic response is provided by the Bode
diagram or frequency response. In this case, a sinusoidal setpoint is applied to
the valve. The frequency up to which the actual value (valve spool) can follow
the setpoint is then noted. The amplitude and phase displacement must be
plotted logarithmically as a function of frequency.

A [dB]
E j [5]
2 5%
0
–2 100
at –3 dB
–4
–6 –180
–8 –160
–10 Signal 100 Umax –140
–120
Signal 5% Umax
–100
at –905
–80
–60
–40
–20
–0
10 20 40 60 80100 200 300 f [Hz]

Fig. A-12 Dynamic response of valve

Filtration grade In order to achieve the longest possible control edge life, thus assuring the qual-
ity of the zero overlap, a certain degree of purity of the hydraulic medium (fluid)
must be maintained.
The objective is contamination class 7...9 to NAS 1638, this can normally be
achieved with a pressure filter β10=75.

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A-240 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 A Hydraulics
A.1 Servo solenoid valves

Hysteresis, These three terms express similar characteristics.

response The term “Hysteresis” refers to the greatest difference in the input signal for
sensitivity, range identical outputs signals on traversal of a full signal range.
of inversion
On a servo solenoid valve, the hysteresis is caused by
S mechanical friction,
S magnetic hysteresis of electromagnetic signal transducer and
S the play between transmission elements.
The position control corrects the hysteresis.
The hysteresis on Bosch closed-loop proportional values is less than 0.2 % and
is compensated for in the closed control loop.
The terms “Response sensitivity” and “Range of inversion” refer to the signal
level required to set a valve in motion again after it has stopped. The values of
these characteristics correspond to about half the hysteresis.
To overcome residual hysteresis or initial valve friction, a friction compensation
function can be activated in the HLA module.

Hysteresis Q

Response sensitivity Q

Range of inversion Q

Fig. A-13 Hysteresis, response sensitivity and range of inversion of servo solenoid valve

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-241
A Hydraulics 02.99
A.1 Servo solenoid valves

A.1.2 Servo solenoid valves of sizes 6 and 10

Mechanical The standard series of size 6 and 10 servo solenoid valves shown in the follow-
construction ing diagram are designed according to the same principle.
The valve spool in its steel sleeve is pushed in contact with the reset spring 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 supply voltage is disconnected, the valve assumes a 4th
position, i.e. 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 rated flows and two different fail-safe
positions.

Size 6 Size 10

7-pin connector Valve amplifier Fail-safe enabled

A B

P T

Fail-safe disabled
A B

P T

Reset spring Valve spool Actuating LVDT coils

solenoid
Steel sleeve Actuating LVDT ferrite core
armature
solenoid coil

Fig. A-14 Sizes 6 and 10 servo solenoid valves, directly actuated

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A-242 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 A Hydraulics
A.1 Servo solenoid valves

Valve amplifier The functions of the integrated valve amplifier are implemented with analog
electronics and illustrated in a block diagram (see Fig. A-15).
The main amplifier functions are:

S Supply and evaluation of the position sensor (AC/DC converter)

S Comparison of setpoint input signal with spool actual value
S Formation of manipulated variable via a PID controller for the output stage
S Timing output stage with pulse length modulation
The amplifier is calibrated to match the valve at the factory. A zero-point adjust-
ment is made via the NC during start-up.

2.5 AF
+24 V=
A 0V Supply
+U B
B
+15V DC 0V Reference point
C Actual value spool
–15 V
DC D value
100k
100k
E Setpoint 0... +
– 10 V
F
10k Sign.
Actual value spool
value
Logic Protective earth

Screening

+U B

+
PID
–

S
U

Fig. A-15 Block diagram of sizes 6 and 10 directly actuated servo solenoid valves

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A Hydraulics 02.99
A.1 Servo solenoid valves

A.1.3 Pilot-actuated sizes 10 and 16 servo solenoid valves

In order to control higher flow rates, the principle of pilot control has been ap-
plied.

Mechanical A directional servo solenoid valve of size 10 or 16 with corresponding control

construction edges on the valve spool functions as the main stage. Like the piston rod of a
cylinder, this stage is hydraulically clamped and positioned by a size 6 pilot
valve (see Section 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 inlet and outlet either internally via ports P and T or, as
hydraulic fluid often the case in practice, externally via additional ports x and y. Plugs are used
to convert the assembly to the desired method.

Positions Pilot-actuated servo solenoid valves have only the three stepless-transition
positions.
They do not have the 4th fail-safe position. If the supply voltage is discon-
nected, the spring force of the main spool causes the valve to assume an indif-
ferent mid-position.

Valve amplifier The integrated valve amplifier is mounted on the pilot valve assembly and con-
tains both position control loops. A cable is used to connect the position sensor
on the main stage to the amplifier.

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A-244 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 A Hydraulics
A.1 Servo solenoid valves

Graphic symbol in detailed form

Graphic symbol in simplified form

Fig. A-16 Pilot-actuated sizes 10 and 16 servo solenoid valves

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-245
A-246
Fig. A-17
2.5 AF
A +24 V=
+U B Supply
A Hydraulics

B 0V
+15V DC C 0V Reference point 1)
–15 V
DC D Actual value spool
100k value
E Setpoint 0... +
Diff. 100k – 10 V
amp.
F Sign. Actual value spool
10k
value
Protective earth
A.1 Servo solenoid valves

Logic
Screening

+U B 1) Do not connect to 0 V
supply
+
PID
+
PD – Pilot
–15 V= stage
1 – Main
ref. 0 stage
2
+15 V=
3 0... +
– 10 V
Signal
4

Block diagram of pilot-actuated sizes 10 and 16 servo solenoid valves

S
U

S
U
02.99

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 Siemens AG 2000. All rights reserved
02.99 A Hydraulics
A.1 Servo solenoid valves

A.1.4 HRV valves

General HRV (High Response Valve) is a series of servo solenoid valves with excellent
dynamic and static characteristics and therefore extends the product range to
cover particularly demanding applications.
The core of the series is the size 6 valve (HRV 1), which is also used
as a pilot valve for the size 10...size 25 (HRV 2) series.
Both valve stages on pilot-actuated valves operate under position control.

Features In comparison to other valves, the HRV series has the following features:

S Significantly better dynamic response

S More compact dimensions
S A higher hydraulic switching capacity.
The HRV valve comprises the following components:

S Flow-force-compensated hydraulic section with wear-resistant steel sleeve

and spring centered control spool,

S Double-stroke solenoid with inductive position encoder (LVDT) and

S Integrated electronics (OBE).
High-response valves do not have the fail-safe position provided on other servo
solenoid valves. Many applications therefore require external non-return valves,
such as those available as sandwich-plate valves.

12-pin connector

Graphic symbol in simplified form

A B
Valve amplifier

P T

Steel sleeve Valve spool Double-stroke Position encoder

solenoid

Fig. A-18 High-response valves

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition A-247
A-248
Fig. A-19
2.5 AF
+24 V=
A Hydraulics

0V Output stage supply

1 24 V
+U B
2 Enable signal
3
4 Setpoint 0...+
– 10 V
100k
5
Logic 100k Sign.
A.1 Servo solenoid valves

6
10k 0V Actual value spool value
7
+15V DC 8 24 V
–15 V

Block diagram of HRV valves

DC 9 Enable acknowledgement
10 +24 V=/<=0.5 A
11 0V Electronics supply
+U B 24 V
Error message
+ Protective earth
PID
+
PD – Screening
1 –
2
+U B
3 0... +
– 10 V
4

S
U HRV
02.99

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 Siemens AG 2000. All rights reserved
02.99 A Hydraulics
A.2 Cylinder

A.2 Cylinder

General The cylinder acts as the drive element in the electrohydraulic control loop.
It converts the flow to a linear movement. In this case, high velocities are re-
quired for rapid traverse movements as well as slow velocities for 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 A
cylinder 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 piston rods on the
through-rod cylinder thus travel in and out symmetrically.
In contrast to the through-rod cylinder, a differential cylinder has either a power-
transmission piston rod at one end only or the piston rods at its two ends 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).
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

A B

D0 D1
Differential cylinder

A B

D2 D0 D1

D1D2

A B

Fig. A-20 Cylinder principle

 Siemens AG 2000. All rights reserved

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A Hydraulics 02.99
A.2 Cylinder

Quality of seals In order to ensure the lowest possible frictional forces, the quality of the seals
and guides on the piston, and the piston rod itself, must be particularly high.
Transitions from static to sliding friction have a particularly adverse affect on the
quality of control accuracy. A friction compensation setting has been provided in
the HLA module (MD 5460: FRICTION_COMP_RADIENT) for the purpose of
counteracting initial friction.

ÌÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌ ÌÌ
ÌÌÌ ÌÌÌ
ÌÌ
ÌÌÌ
ÌÌÌ
ÌÌ
ÌÌ
ÌÌÌÌÌÌÌÌÌÌÌÌ
ÌÌÌÌ Ì
Ì
ÌÌ
Ì
Piston rod

Piston

2 x guide ring
(PTFE)

ÌÌ
ÌÌ Ì ÌÌ Ì ÌÌÌ
ÌÌ ÌÌÌÌÌÌ
2 x guide ring Stabilizing ring
Seal (PTFE) (FPM)
(FPM+PTFE)

2 x sealing ring
(FPM+PTFE)

Fig. A-21 Cylinders

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 parameterized in the HLA module (MD 5135, MD 5136 and
MD 5141...5143).
J

 Siemens AG 2000. All rights reserved

A-250 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Abbreviations B
A Working port on cylinder
ANA Analog drive
ARM (MSD) Asynchronous rotation motor (main spindle drive)
AS Automation System
AT Advanced Technology
B Working port on cylinder

BERO Proximity limit switch

COM Communication Module

DAC Digital/analog converter channel

D/A Digital to Analog

DP Distributed Peripherals (I/Os)

DRV Driver Module

DSC Dynamic Stiffness Control

EMC Electromagnetic Compatibility
ESD Modules/components endangered by electrostatic discharge
EUS End User Interfaces
FDD Feed Drive

FFT Fast Fourier Transform

FRM Enabling voltage internal ground

FRP Enabling voltage internal +24 V

HD Hard Disk

HHU Handheld Unit

HLA Hydraulic Linear Drive

HRV High Response Valve
HYD Hydraulic Drive
I/RF Infeed/Regenerative Feedback Module
IM Interface Module (SIMATIC S7-300)

IM Address Interface Module Address

ISA Industry Standard Architecture

K Bus Communication Bus

LED Light Emitting Diode

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition B-251
B Abbreviations 02.99

LVDT Linear Variable Differential Transducer

M24EXTIN External 0 V input
MCP Machine Control Panel
MD Machine Data
MLFB Machine-readable product designation (Order No.)
MMC Man Machine Communication
MPI MultiPoint Interface
MSD Main Spindle Drive
NC Numerical Control
NCU Numeric Control Unit
NE Mains Infeed (module)
NMI Non-Maskable Interrupt
OBE On-Board Electronics

OP Operator Panel
OPI Operator Panel Interface
P Pressure port (inlet), servo solenoid valve
P24EXTIN External +24 V input
PBL Parameter Basic List
P Bus I/O Bus
PCL Position Control Loop
PCMCIA Personal Computer Memory Card International Association
PER I/O Module
PG Programming Unit
PI Program Invocation
PID Controller with Proportional, Integral and Differential components
PLC Programmable Logic Controller
PS Power Supply (SIMATIC S7-300)
RK Control loop
SCI Serial Communication Control
SLM Synchronous Linear Motor
SM Signal Module of SIMATIC S7-300, e.g. I/O modules
SRM (FDD) Synchronous Rotation Motor (feed drive)
SW Software
T Tank port (return), servo solenoid valve

Term. Terminal
UE Unregulated incoming supply

 Siemens AG 2000. All rights reserved

B-252 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 B Abbreviations

ÜW Monitoring
VCL Velocity Control Loop
VGA Video Graphics Adapter
ZK Status class

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition B-253
B Abbreviations 02.99

Notes

 Siemens AG 2000. All rights reserved

B-254 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
Definition of Terms C
A Cylinder piston surface

D1, D2 Cylinder piston diameter

d1, d2 Cylinder piston rod diameter

f0drive Natural frequency (resonant frequency) of hydraulic drive

f0control Limit frequency that can be achieved by velocity-controlled drive

f0valve Natural frequency of servo solenoid valve

fv Limit frequency of servo solenoid valve

h Cylinder stroke

hx Stroke at which min. natural frequency occurs

m Mass on piston rod

pA Pressure at A end of cylinder

pB Pressure at B end of cylinder

pp Pump pressure

∆p Pressure difference (rated pressure drop)

∆pPA Pressure drop in the feed pipe

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition C-255
C Definition of Terms 02.99

∆pBT Pressure drop in the discharge pipe

Qnom Rated flow of servo solenoid valve

Qvalve Servo solenoid valve flow

Uset valve Valve setpoint

vset Velocity setpoint

vact Actual velocity

xset Position setpoint

xact Actual position

xvalve Valve spool position

 Siemens AG 2000. All rights reserved

C-256 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
References D
D.1 Electrical applications

General Documentation

/BU/ SINUMERIK 840D/810D/FM-NC

Ordering Information
Catalog NC 60.1
Order No.: E86060-K4460-A101-A6-7600

/ST7/ SIMATIC
SIMATIC S7 Programmable Logic Controllers
Catalog ST 70
Order No.: E86 060-K4670-A111-A3

/VS/ SINUMERIK 840D/810D/FM-NC

Technical Information
Catalog NC 60.2
Order No.: E86060-D4460-A201-A4-7600

/W/ SINUMERIK 840D/810D/FM-NC

Brochure

/Z/ SINUMERIK, SIROTEC, SIMODRIVE

Accessories and Equipment for Special-Purpose Machines
Catalog NC Z
Order No.: E86060-K4490-A001-A6-7600

Electronic Documentation

/CD6/ The SINUMERIK System (04.00 Edition)

DOC ON CD
(includes all SINUMERIK 840D/810D/FM-NC and SIMODRIVE 611D
publications)
Order No.: 6FC5 298-5CA00-0BG2

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition D-257
D References 04.00
02.99

User Documentation
/AUE/ SINUMERIK 840D/810D/FM-NC
AutoTurn Graphic Programming System (07.99 Edition)
Operator’s Guide
Part 2: Setup
Order No.: 6FC5 298-4AA50-0BP2

/AUK/ SINUMERIK 840D/810D/FM-NC

Short Guide AutoTurn Operation (07.99 Edition)
Order No.: 6FC5 298-4AA30-0BP2

/AUP/ SINUMERIK 840D/810D/FM-NC

AutoTurn Graphic Programming System (07.99 Edition)
Operator’s Guide
Part 1: Programming
Order No.: 6FC5 298-4AA40-0BP2

/BA/ SINUMERIK 840D/810D/FM-NC

Operator’s Guide (04.00 Edition)
Order No.: 6FC5 298-5AA00-0BP2
– Operator’s Guide
– Operator’s Guide Interactive Programming (MMC 102/103)

/BAE/ SINUMERIK 840D/810D/ FM-NC

Operator’s Guide Unit Operator Panel (04.96 Edition)
Order No.: 6FC5 298-3AA60-0BP1

/BAH/ SINUMERIK 840D/810D

Operator’s Guide HT6 (HPU new) (06.00 Edition)
Order No.: 6FC5 298-0AD60-0BP0

/BAK/ SINUMERIK 840D/810D/FM-NC

Short Operation Guide (12.98 Edition)
Order No.: 6FC5 298-5AA10-0BP0

/BAM/ SINUMERIK 840D/810D

Operator’s Guide ManualTurn (12.99 Edition)
Order No.: 6FC5 298-5AD00-0BP0

/KAM/ SINUMERIK 840D/810D

Short Guide ManualTurn (11.98 Edition)
Order No.: 6FC5 298-2AD40-0BP0

/BAS/ SINUMERIK 840D/810D

Operator’s Guide ShopMill (11.99 Edition)
Order No.: 6FC5 298-5AD10-0BP1

/KAS/ SINUMERIK 840D/810D

Short Guide ShopMill (01.98 Edition)
Order No.: 6FC5 298-2AD30-0BP0

 Siemens AG 2000. All rights reserved

D-258 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
02.99 D References

/BAP/ SINUMERIK 840D/840Di/810D

Operator’s Guide Handheld Programming Unit (04.00 Edition)
Order No.: 6FC5 298-5AD20-0BP1

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

User’s Guide Measuring Cycles (04.00 Edition)
Order No.: 6FC5 298-5AA70-0BP2

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

Diagnostics Guide (04.00 Edition)
Order No.: 6FC5 298-5AA20-0BP2

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

Programming Guide Fundamentals (04.00 Edition)
Order No.: 6FC5 298-5AB00-0BP2

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

Programming Guide Advanced (04.00 Edition)
Order No.: 6FC5 298-5AB10-0BP2

/PGK/ SINUMERIK 840D/810D/FM-NC

Short Guide Programming (12.98 Edition)
Order No.: 6FC5 298-5AB30-0BP0

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

Programming Guide Cycles (04.00 Edition)
Order No.: 6FC5 298-5AB40-0BP2

/PI/ PCIN 4.4

Software for Data Transfer to/from MMC Module
Order No.: 6FX2 060 4AA00-4XB0 (German, English, French)
Order from: WK Fürth

/SYI/ SINUMERIK 840Di

System Overview (06.00 Edition)
Order No.: 6FC5 298-5AE40-0BP0

Manufacturer/Service Documentation

a) Lists

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

SIMODRIVE 611D
Lists (04.00 Edition)
Order No.: 6FC5 297-5AB70-0BP2

b) Hardware

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

Operator Components Manual (HW) (04.00 Edition)
Order No.: 6FC5 297-5AA50-0BP2

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition D-259
D References 04.00
02.99

/BHA/ SIMODRIVE Sensor

Absolute Encoder with Profibus DP
User Guide (HW) (02.99 Edition)
Order No.: 6SN1197-0AB10-0BP1

/EMV/ SINUMERIK, SIROTEC, SIMODRIVE

EMC Installation Guide
Planning Guide (HW) (06.99 Edition)
Order No.: 6FC5 297-0AD30-0BP1

/PHC/ SINUMERIK 810D

Manual Configuring (HW) (04.00 Edition)
Order No.: 6FC5 297-3AD10-0BP2

/PHD/ SINUMERIK 840D

NCU 561.2–573.2 Configuring Manual (HW) (04.00 Edition)
Order No.: 6FC5 297-5AC10-0BP2

/PHF/ SINUMERIK FM-NC

NCU 570 Configuring Manual (HW) (04.96 Edition)
Order No.: 6FC5 297-3AC00-0BP0

/PMH/ SIMODRIVE Sensor (05.99 Edition)

Measuring System for Main Spindle Drives
Configuring/Installation Guide, SIMAG-H (HW)
Order No.: 6SN1197-0AB30-0BP0

c) Software

/FB1/ SINUMERIK 840D/840Di/810D/FM-NC

Description of Functions, Basic Machine (Part 1) (04.00 Edition)
(the various sections are listed below)
Order No.: 6FC5 297-5AC20-0BP2
A2 Various Interface Signals
A3 Axis Monitoring, Protection Zones
B1 Continuous Path Mode, Exact Stop and Look Ahead
B2 Acceleration
D1 Diagnostic Tools
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 Compensation

 Siemens AG 2000. All rights reserved

D-260 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
02.99 D References

/FB2/ SINUMERIK 840D/840Di/810D(CCU2)/FM-NC

Description of Functions, Extended Functions (Part 2) (04.00 Edition)
including FM-NC: Turning, Stepper Motor
(the various sections are listed below)
Order No.: 6FC5 297-5AC30-0BP2
A4 Digital and Analog NCK I/Os
B3 Several Operator Panels and NCUs
B4 Operation via PG/PC
F3 Remote Diagnostics
H1 Jog with/without Handwheel
K3 Compensations
K5 Mode Groups, Channels, Axis Replacement
L1 FM-NC Local Bus
M1 Kinematic Transformation
M5 Measurement
N3 Software Cams, Position Switching Signals
N4 Punching and Nibbling
P2 Positioning Axes
P5 Oscillation
R2 Rotary Axes
S3 Synchronous Spindles
S5 Synchronized Actions (up to and including SW 3)
S6 Stepper Motor Control
S7 Memory Configuration
T1 Indexing Axes
W3 Tool Change
W4 Grinding

/FB3/ SINUMERIK 840D/840Di/810D(CCU2)/FM-NC

Description of Functions, Special Functions (Part 3) (04.00 Edition)
(the various sections are listed below)
Order No.: 6FC5 297-5AC80-0BP2
F2 3-Axis to 5-Axis Transformation
G1 Gantry Axes
G3 Cycle Times
K6 Contour Tunnel Monitoring
M3 Coupled Motion and Leading Value Coupling
S8 Constant Workpiece Speed for Centerless Grinding
T3 Tangential Control
V2 Preprocessing
W5 3D Tool Radius Compensation
TE1 Clearance Control
TE2 Analog Axis
TE3 Master-Slave for Drives
TE4 Transformation Package Handling
TE5 Setpoint Exchange
TE6 MCS Coupling

/FBA/ SIMODRIVE 611D/SINUMERIK 840D/810D

Description of Functions, Drive Functions (04.00 Edition)
(the various sections are listed below)
Order No.: 6SN1 197-0AA80-0BP6
DB1 Operational Messages/Alarm Reactions
DD1 Diagnostic Functions
DD2 Speed Control Loop
DE1 Extended Drive Functions

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition D-261
D References 04.00
02.99

DF1 Enable Commands

DG1 Encoder Parameterization
DM1 Calculation of Motor/Power Section Parameters and
Controller Data
DS1 Current Control Loop
DÜ1 Monitors/Limitations

/FBAN/ SINUMERIK 840D/SIMODRIVE 611D Digital

Description of Functions
ANA Module (11.99 Edition)
Order No.: 6SN1 197-0AB80-0BP0

/FBD/ SINUMERIK 840D

Description of Functions Digitizing (07.99 Edition)
Order No.: 6FC5 297-4AC50-0BP0
DI1 Start-up
DI2 Scanning with Tactile Sensors (scancad scan)
DI3 Scanning with Lasers (scancad laser)
DI4 Milling Program Generation (scancad mill)

/FBDN/ CAM Integration DNC NT-2000

Description of Functions
System for NC Data Management and Data Distribution (10.99 Edition)
Order No.: 6FC5 297-5AE50-0BP0

/FBFA/ SINUMERIK 840D/810D

Description of Functions
ISO Dialects for SINUMERIK (04.00 Edition)
Order No.: 6FC5 297-5AE10-0BP1

/FBHLA/ SINUMERIK 840D/SIMODRIVE 611 digital

Description of Functions
HLA Module (08.99 Edition)
Order No.: 6SN1 197-0AB60-0BP1

/FBMA/ SINUMERIK 840D/810D

Description of Functions ManualTurn (12.99 Edition)
Order No.: 6FC5 297-5AD50-0BP0

/FBO/ SINUMERIK 840D/810D/FM-NC

Description of Functions (03.96 Edition)
Configuring of Operator Interface OP 030
(the various sections are listed below)
Order No.: 6FC5 297-3AC40-0BP0
BA Operator’s Guide
EU Development Environment (Configuring Package)
PS Online only: Configuring Syntax (Configuring Package)
PSE Introduction to Configuring of Operator Interface
IK Screen Kit: Software Update and Configuration

/FBP/ SINUMERIK 840D

Description of Functions C-PLC Programming (03.96 Edition)
Order No.: 6FC5 297-3AB60-0BP0

 Siemens AG 2000. All rights reserved

D-262 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
02.99 D References

/FBR/ SINUMERIK 840D/810D

Description of Functions
SINCOM Computer Link (02.00 Edition)
Order No.: 6FC5 297-5AD60-0BP0
NFL Host Computer Interface
NPL PLC/NCK Interface

/FBSI/ SINUMERIK 840D/SIMODRIVE

Description of Functions SINUMERIK Safety Integrated (05.00 Edition)
Order No.: 6FC5 297-5AB80-0BP1

/FBSP/ SINUMERIK 840D/810D

Description of Functions ShopMill (05.00 Edition)
Order No.: 6FC5 297-5AD80-0BP1

/FBST/ SIMATIC
FM STEPDRIVE/SIMOSTEP (01.97 Edition)
Description of Functions
Order No.: 6SN1 197-0AA70-0BP3

/FBSY/ SINUMERIK 840D/810D

Description of Functions Synchronized Actions (04.00 Edition)
for Wood, Glass, Ceramics, Presses
Order No.: 6FC5 297-5AD40-0BP2

/FBTD/ SINUMERIK 840D/810D

Description of Functions
Tool Information SINTDI with Online Help (04.99 Edition)
Order No.: 6FC5 297-5AE00-0BP0

/FBU/ SIMODRIVE 611 universal

Description of Functions (10.99 Edition)
Closed-Loop Control Component for Speed Control and Positioning
Order No.: 6SN1 197-0AB20-0BP2

/FBW/ SINUMERIK 840D/810D

Description of Functions Tool Management (04.00 Edition)
Order No.: 6FC5 297-5AC60-0BP2

/HBI/ SINUMERIK 840Di

Manual (06.00 Edition)
Order No.: 6FC5 297-5AE50-0BP0

/IK/ SINUMERIK 840D/810D/FM-NC

Screen Kit MMC 100/Unit Operator Panel (06.96 Edition)
Description of Functions: Software Update and Configuration
Order No.: 6FC5 297-3EA10-0BP1

/KBU/ SIMODRIVE 611 universal

Short Description (10.99 Edition)
Closed-Loop Control Component for Speed Control
Order No.: 6SN1 197-0AB40-0BP2

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition D-263
D References 04.00
02.99

/PJLM/ SIMODRIVE
Planning Guide Linear Motors (02.00 Edition)
(on request)
ALL General Information about Linear Motors
1FN1 1FN1 Three-Phase AC Linear Motor
1FN3 1FN3 Three-Phase AC Linear Motor
CON Connections
Order No.: 6SN1 197-0AB70-0BP1

/PJM/ SIMODRIVE
Planning Guide Motors (01.98 Edition)
Three-Phase AC Motors for Feed and
Main Spindle Drives
Order No.: 6SN1 197-0AA20-0BP3

/PJU/ SIMODRIVE 611-A/611-D

Planning Guide Inverters (08.98 Edition)
Transistor PWM Inverters for
AC Feed Drives and AC Main Spindle Drives
Order No.: 6SN1 197-0AA00-0BP4

/POS1/ SIMODRIVE POSMO A

User Manual (02.00 Edition)
Distributed Positioning Motor on PROFIBUS DP
Order No.: 6SN2 197-0AA00-0BP1

/POS2/ SIMODRIVE POSMO A

Installation Instructions (enclosed with POSMO A) (12.98 Edition)
Order No.: 462 008 0815 00

/S7H/ SIMATIC S7-300 (10.98 Edition)

– Manual: Assembly, CPU Data (HW)
– Reference Manual: Module Data
Order No.: 6ES7 398-8AA03-8AA0

/S7HT/ SIMATIC S7-300 (03.97 Edition)

Manual: STEP 7, Basic Information, V3.1
Order No.: 6ES7 810-4CA02-8AA0

/S7HR/ SIMATIC S7-300 (03.97 Edition)

Manual
STEP 7, Reference Manuals, V3.1
Order No.: 6ES7 810-4CA02-8AR0

/S7S/ SIMATIC S7-300 (04.97 Edition)

FM 353 Step Drive Positioning Module
Order in conjunction with Configuring Package

/S7L/ SIMATIC S7-300 (04.97 Edition)

FM 354 Servo Drive Positioning Module
Order in conjunction with Configuring Package

 Siemens AG 2000. All rights reserved

D-264 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
02.99 D References

/S7M/ SIMATIC S7-300 (10.99 Edition)

FM 357 Multi-Axis Module for Servo and Stepper Drives
Order in conjunction with Configuring Package

/SHM/ SIMODRIVE 611 (01.98 Edition)

Manual Single-Axis Positioning for MCU 172A
Order No.: 6SN 1197-4MA00-0BP0

/SP/ SIMODRIVE 611-A/611-D, SimoPro 3.1

Program for Configuring Machine-Tool Drives
Order No.: 6SC6 111-6PC00-0AAj
Order from: WK Fürth

d) Installation and
start-up

/IAA/ SIMODRIVE 611A

Installation and Start-Up Guide (04.00 Edition)
Order No.: 6SN 1197-0AA60-0BP5

/IAC/ SINUMERIK 810D

Installation and Start-Up Guide (04.00 Edition)
(incl. description of SIMODRIVE 611D start-up software)
Order No.: 6FC5 297-3AD20-0BP2

/IAD/ SINUMERIK 840D/SIMODRIVE 611D

Installation and Start-Up Guide (04.00 Edition)
(incl. description of SIMODRIVE 611D start-up software)
Order No.: 6FC5 297-5AB10-0BP2

/IAF/ SINUMERIK FM-NC

Installation and Start-Up Guide (04.96 Edition)
Order No.: 6FC5 297-3AB00-0BP0

/IAM/ SINUMERIK 840D/810D

MMC Installation and Start-Up Guide (04.00 Edition)
Order No.: 6FC5 297-5AE20-0BP2
IM1 Start-up functions for the MMC 100.2
IM3 Start-up functions for the MMC 103
IM4 Start-up functions for HMI Advanced (PCU 50)
HE1 Editor help
BE1 Supplement operator interface

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition D-265
D References 04.00
02.99

D.2 Hydraulic applications

/AKY013/2/ Robert Bosch GmbH

“Servo solenoid valves” catalog

/AKY013/4/ Robert Bosch GmbH

“Sensors and electronics” catalog

/USY013/3/ Robert Bosch GmbH

“Electro-hydraulic proportional and control engineering” catalog

 Siemens AG 2000. All rights reserved

D-266 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
EC Declaration of Conformity E
Note
An extract from the EC Declaration of Conformity No. E002 V 25/02/99 is
shown below. A complete copy of the EC Declaration of Conformity can be
found in the “EMC Installation Guidelines” for the SINUMERIK, SIROTEC and
SIMODRIVE controls.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition E-267
E EC Declaration of Conformity 02.99

 Siemens AG 2000. All rights reserved

E-268 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99 E EC Declaration of Conformity

Appendix A to EC Declaration of Conformity No. E002 V 25/02/99

A16: Typical plant configuration

SINUMERIK 840D/SIMODRIVE 611D with closed-loop
hydraulics module (HLA)
Metal cabinet

Operator panel

Machine
control panel

611D
Fil- 840D
with Actual pressure
ter
HLD
*) Actual position

**) *)
Fil-
ter

Throttle
Mains terminal
Setpoint
*) with I/RF module
**)with UE 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.

S For compliance with standards, see Appendix C

Note:
The plant configuration sketch illustrates only the basic measures to be implemented in a typical plant
configuration to ensure compliance with Directive 89/336/EEC.
In addition, especially in cases where the plant configuration deviates from this
typical model, the installation guidelines for EMC plant design in the product documentation and
the EMC installation guidelines for SINUMERIK, SIROTEC and SIMODRIVE (order no.:
6FC5297-0AD30-0BP0) must be noted and implemented.

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition E-269
E EC Declaration of Conformity 02.99

Appendix C to EC Declaration of Conformity No. E002 V 25/02/99

C: The compliance of the products with Council Directive 89/336/EEC has been verified
through inspection and testing in accordance with the following product standard, basic
technical specifications and the basic standards contained therein. Product categories
SINUMERIK, SIROTEC, SIMODRIVE and SIMATIC are subject to the requirements of
different standards.

C1 Product categories SINUMERIK*), SIMATIC, SIROTEC:

Basic specification: EN 50081-2 dated 8/93 1)
Basic standards: Subject of tests:
EN 55011 2) Radio interference
Basic specification: EN 50082-2 dated 3/95 3)
Basic standards: Subject of tests:
EN 61000-4-3 4) Radiated radio frequency field (amplitude-modulated)
ENV 50204 5) Radiated radio frequency field (pulse-modulated)
EN 61000-4-6 6) Conducted disturbances
EN 61000-4-8 7) Power frequency magnetic fields
EN 61000-4-2 8) Electrostatic discharge
EN 61000-4-4 9) Electrical fast transient bursts
*) except for SINUMERIK 810D

C2 Product categories SIMODRIVE, SINUMERIK 810D:

Product standard: EN 61800-3 10)

C3 Other standards complied with:

1) VDE 0839 Part 81-2 6) IEC 801-6,
VDE 0847 Part 4-6
IEV 1000-4-6
ENV 50141
2) VDE 0875 Part 11 7) VDE 0847 Part 4-8
IEC 1000-4-8
3) VDE 0839 Part 82-2 8) VDE 0847 Part 4-2
EN 60801 Part 2
IEC 801-2
VDE 0843 Part 2
4) VDE 0847 Part 4-3 9) VDE 0843 Part 4
ENV 50140 VDE 0847 Part 4-4
IEC 801-4
5) VDE 0847 Part 204 10) VDE 0160 Part 100

 Siemens AG 2000. All rights reserved

E-270 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
02.99

Index
Closed-loop velocity control
F
Acceleration feedback, 4-111
Adaptation of D component, 4-108
Adaptation of P component, 4-108
A D component, 4-111
Abbreviations of drive types, 3-53 I component, 4-110
Acceleration feedback, 4-111 Integrator feedback, 4-110
Acceleration limitation, 4-106 P component, 4-109
Achievable dynamic response, 4-97 Reference model, 4-112
Activation of DAC output, 5-181 Velocity controller cycle, 4-107
Activation of data, 3-60 Comparison of electrical and hydraulic drive
Adaptation, 4-108 systems, 1-16
Air pressure, 5-183 Configuring an OEM valve list, 3-94
Analogy of characteristic data, 1-17 Example of an OEM valve list, 3-94
Format, 3-94
General, 3-94
Language-dependent OEM texts, 3-96
B Language-dependent system texts, 3-96
Block diagram of control functions, 4-98 Language-dependent texts, 3-96
Configuring steps, 2-21
electrical, 2-21
hydraulic, 2-22
C Configuring the hydraulic drive, 2-30
Characteristic compensation Cylinder selection, 2-30
Area adaptation, 4-125 Hydraulic power unit, 2-44
Friction, 4-107 Natural frequency, 2-42
Linearization of valve, 4-126 selection of servo solenoid valve, 2-32
Offset, 4-129 Selection of shutoff valve, 2-39
Characteristics of servo solenoid valves Connection and power loss calculation for NCU,
Dynamic response, A-239 2-46
Filtration grade, A-240 Connection configuration for HLA module, 2-27
Hysteresis, A-241 Connection of 24 V supply
Linearization of knee-shaped characteristic, with shutoff valve, 4-146
A-238 without shutoff valve, 4-146
Pressure intensification, A-236 Construction of an electro-hydraulically controlled
Range of inversion, A-241 drive axis, 1-18
Rated flowrate, A-239 Control direction
Response sensitivity, A-241 Determine control direction, 3-64
Circularity test, 3-90 General, 3-64
Climatic environmental conditions, 5-183 Limitation of manipulated voltage, 3-64
Closed–loop force control Control output, velocity controller, 4-113
Start-up, 4-116 Controlled system gain|, 4-106
Static friction injection, 4-119 Controller adaptation
Closed-loop control functions, 4-100 General, 3-75
Closed-loop force control, 4-116 Implementation, 3-75
Configuration, 4-117 Controller data/Calculate drive model data, 3-63
Force controller, 4-120
Force limitation, 4-116, 4-118
Preconditions, 4-116

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition Index-271
Index 04.00
02.99

Controller optimization, 3-63 Filter, Control output, velocity controller, 4-113

D response, 3-73 Filters, Velocity setpoint filters, 4-101
General, 3-70 Fine adjustment and optimization, 3-64
I response, 3-74 Force controller
P response, 3-73 Controlled system gain, 4-121
Cylinder D component, 4-122
Construction, 1-19 Feedforward control filter, 4-123
Dead volume, A-250 Feedforward control gain, 4-120
Differential cylinder, A-249 I component, 4-122
General, A-249 P component, 4-121
Quality criteria, 1-19 Function generator, 3-86
Quality of seals, A-250 Position setpoint, 3-89
Through-rod cylinder, A-249 Signal types, 3-86
Cylinder data, 4-136 Signals, 3-86
Cylinder drive, Cylinder data, 4-136 Start-up of force controller, 4-116
Cylinder selection, 3-58 Valve spool setpoint, 3-87
Cylinder pipes, 2-31 Velocity setpoint, 3-88
Friction, 2-31
Mounting, 2-31
Mounting position, 2-31
Piston diameter, 2-30
H
Position measuring system, 2-31 Hydraulic drive unit, Drive power, 2-44
Rod diameter, 2-30 Hydraulic power pack, Cooling, 2-44
Seal, 2-31 Hydraulic power unit, 1-20
Stroke length, 2-30 Filtration, 2-44
Flow, 2-44
Pressure, 2-44
Pump type, 2-44
D
D component, 4-111
DAC assignments, 5-180
DAC parameterization, 3-91
I
DAC selection list, 3-91 I component, 4-110
DC supplies, 2-46 Integrator feedback, 4-110
Dew-point temperature td, 5-183 Interfaces
Display options, 3-93 Firmware, 1-15
Drive data Hardware, 1-15
Dynamic model data, 4-139
Mechanical drive components, 4-137
Valve-to-drive connection, 4-137
Drive machine data, 3-54
L
Drive model data, Changing valve data, 3-61 List selection of valve, 3-56
Dust, harmful, 5-185 Loaded valve data, 3-56
Dynamic drive model data, 4-139
Dynamic Stiffness Control (DSC), 4-115
M
Machine configuration, 3-51
E Machine data groups, 3-93
Earthing system, 2-49 Machine guideway
Error reactions, 6-187 Friction, 1-18
Examples of applications, 1-15 Guide mechanism, 1-18
Mains connection, 5-182
Manipulated variable inversion, 4-132
Manipulated voltage limitation, 4-132
F Measurement function
Feasible dynamics, 2-43 Measurement of position control loop, 3-84
File functions Measurement of velocity controller, 3-80
Loading data, 3-77 Measuring function, Valve control loop
Saving data, 3-77 measurement, 3-79

 Siemens AG 2000. All rights reserved

Index-272 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
04.00
02.99 Index

Measuring system, 5-176 Position measuring system, 4-140

Measuring system data, 3-60 Actual position, 4-142
absolute, 3-60 Description, 4-140
incremental, 3-60 Function, 1-20
Mechanical drive components, 4-137 Minimum and maximum velocity, 4-140
Mechanical environmental conditions, 5-183 Phase error compensation, 4-140
Message Position measuring system, linear scale
SMRDY, 4-149 graduations|, 4-141
Valve spool is not responding, 4-152 Task, 1-19
Velocity controller at limit, 4-151 Power disable, 4-147, 4-148
Monitoring functions, 4-150 Power enable, 4-147
Measuring circuit, 4-150 Power supply
Measuring circuit limit frequency reached, external, 2-46
4-151 internal, 2-46
Power On alarms, 4-150 Preset unlisted valve, 3-57
Mounting the HLA closed-loop control plug-in Pressure sensors, 4-143, 5-177
module, 2-29 Offset adjustment, 4-143
Mounting/supply data Sensor adjustment, 4-143
Connection, 3-59
Drive data, 3-59
Supply unit, 3-59
R
Reference model, 4-112
References, D-257
N Referencing data for HLA
Natural frequency of the hydaulic drive, Feasible Adjustment of piston position, 3-69
dynamics, 2-43 Piston neutral position, 3-69
Natural frequency of the hydraulic drive, Servo Relative air humidity U, 5-183
gain, 2-42 Requirements of external 26,5 V supply, 2-46
NE module interfaces, 2-28

S
O Selection of servo solenoid valves
Objective, 1-15 Asymmetrical characteristics, 2-35
Offset adjustment Characteristic, 2-34
Manipulated valve voltage offset, 3-67 Connector pin assignments, 2-36
Offset of pressure sensors, 3-66 Fail-safe position, 2-35
Reference value for pressure sensors, 3-67 HRV valves, 2-34
Options, 7-217 Preferred range of servo solenoid valves, 2-36
Output of manipulated variables, 4-125 Servo solenoid valves, 2-34
Output voltage range of DAC outputs, 5-181 Valve size, 2-33
Overview of functions, HLA firmware, 4-99 Valve types, 2-32
Overview of HLA machine data, 4-163 Selection of shutoff valves
Overview of start-up process for hydraulics General, 2-39
module, 3-51 Preferred range of shutoff valves, 2-41
Selection of valve, from list, 3-56
Service functions
Diagnostic machine data, 4-159
P Min/max display, 4-157
P component, 4-109 Monitor, 4-158
Parameter set changeover, 4-99 Servo solenoid valve
Pollutants, 5-185 Function, 1-19
Position adjustment, 3-69 Task, 1-19

 Siemens AG 2000. All rights reserved

SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition Index-273
Index 04.00
02.99

Servo solenoid valves V

Features of HRV valves, A-247
Flow characteristic linear, A-237 Valve amplifier, 1-19
Flow characteristic, knee-shaped, A-238 Valve data, 4-134
Graphic symbol, A-234 Valve list
HRV valves, A-247 Example of an OEM valve list, 3-94
Mechanical construction, A-242 Format, 3-94
Pilot control principle, A-244 General, 3-94
Solenoid actuation with position control of Language-dependent OEM texts, 3-96
valve spool, A-234 Language-dependent system texts, 3-96
Spool principle, A-233 Language-dependent texts, 3-96
Zero overlap in mid-position, A-236 Valve selection
Shipment conditions, 5-184 General, 3-55
Shock resistance, 5-183 Loaded valve data, 3-56
Shutoff valve, 1-19 Unlisted valve data, 3-57
Start-up flow chart Valve selection softkey, 3-55
Definition of drive travel direction, 3-65, 3-66 Velocity adjustment, Adjustment of controlled
Determine control direction, 3-65 system gain, 3-68
Start-up sequence, 3-52 Velocity compensation, Objective, 3-67
Start-up support, Disabled softkeys, 3-78 Velocity control, Control output filter, 4-113
Static friction injection Velocity controller, 4-107
Cutoff limit, 4-119 Velocity controller cycle, 4-107
Cylinder friction force, 4-120 Velocity controller disable, 4-149
Velocity threshold, 4-119 Velocity controller enable, 4-148
Storage conditions, 5-184 Velocity feedforward control, 4-100
Supply unit data, 4-133 Acceleration limitation, 4-106
System components, 2-26 Controlled system gain|, 4-106
System overview Friction, 4-107
Components, 2-24 Velocity feedforward control, 4-100
Mounting the HLA closed-loop control plug-in Velocity setpoint filters, 4-101
module, 2-29 Velocity setpoint interpolation, 4-100
Velocity setpoint limitation, 4-106
Velocity setpoint adaptation, 4-100
Velocity setpoint filters, 4-101
T Velocity setpoint interpolation, 4-100
Terminals, 4-144, 5-179 Velocity setpoint limitation, 4-106
Error reactions, 6-187 Vibration resistance, 5-183
External 24 V supply, 4-144
Function switch, 4-149
ON/OFF sequence, 4-144 W
Power disable, 4-147, 4-148
Power enable, 4-147 Weighting factor, 2-46
Setup mode, 4-149
Velocity controller disable, 4-149
Velocity controller enable, 4-148 X
Travel direction
Cancel manipulated voltage limitation, 3-66 X101, 5-176
Definition of drive travel direction, 3-65 X102, 5-176
Definition of travel direction in NC, 3-66 X111, 5-177
Determine control direction, 3-64 X112, 5-177
Limitation of manipulated voltage, 3-64 X121, 5-178
X122, 5-178
X141, 5-181
X151, 5-181
U X341, 5-181
Unlisted valve data, 3-57 X431, 5-179
X432, 5-179

 Siemens AG 2000. All rights reserved

Index-274 SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) – 04.00 Edition
 Suggestions
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A&D MC IS For Publication/
P.O. Box 3180 Manual:
SINUMERIK 840D
D–91050 Erlangen, Germany SIMODRIVE 611 digital
Description of Functions
(Tel. 0180/538–8008 [Hotline] HLA Module
Fax +49 9131/98–1145
email: [email protected]) Manufacturer/Service Documentation

Description of Functions
From
Order No.: 6SN1197–0AB60–0BP2
Name Edition: 04.00

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