siemens 611 User Manual

SIMODRIVE 611 digital

HLA module

Description of Functions

Valid for

Series 6SN11-

03.06 Edition

General Information

Configuration

Start-up

Firmware Drive Functions

Hardware Drive Functions

Hydraulics Diagnostics

Peripherals/Accessories

Servicing

Hydraulics

Abbreviations

Terminology

References

EC Declaration of

Conformity

Index

1

2

3

4

5

6

7

8

A B C D

E F

3ls	SINUMERIK→ Documentation

Revision history

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

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

Status code in the “Remarks” column:

A . . . . . New documentation.

B . . . . . Unmodified reprint with new order number C . . . . . Revised version with new edition status.

If the technical subject matter shown on the page has changed compared to the previous edition status, this is indicated by the changed edition status in the header of the respective page.

Edition	Order no.	Remarks
02/99	6SN1197-0AB60-0BP0	A
08/99	6SN1197-0AB60-0BP1	C
04/00	6SN1197-0AB60-0BP2	C
10/03	6SN1197-0AB60-0BP3	C
03/06	6SN1197-0AB60-0BP4	C

Trademarks

All products are registered trademarks of Siemens AG. Other names in this publication might be trademarks whose use by a third party for his own purposes may violate the rights of the registered holder.

	Other functions not described in this documentation might be
	executable in the control. This does not, however, represent an
	obligation to supply such functions with a new control or when
	servicing.
	We have checked that the contents of this document correspond to
	the hardware and software described. Nevertheless, differences
	might exist and therefore we cannot guarantee that they are
	completely identical. The information given in this publication is
	reviewed at regular intervals and any corrections that might be
	necessary are made in subsequent editions. We welcome all
	recommendations and suggestions.
♥ Siemens AG, 2006.	Subject to change without prior notice

Printed in Germany

Siemens Aktiengesellschaft.

1032.06993

Preface

Preface

Structure of the documentation

Target group

Benefits

Technical support

Instructions when reading

The SIMODRIVE documentation is subdivided into 2 parts:

SGeneral Documentation

SManufacturer/Service Documentation

The function manual of the HLA module is part of the

SIMODRIVE/SINUMERIK documentation.

A list of documents, updated on a monthly basis, is available on the Internet for the available languages at:

http://www.siemens.com/motioncontrol

Select “Support” ––> “Technical Documentation” ––> “Overview of Documents”

The Internet version of the DOConCD (DOConWEB) is available at: http://www.automation.siemens.com/doconweb

You can find information on the training courses offered and FAQs (frequently asked questions) on the Internet under: http://www.siemens.com/motioncontrol (under “Support”)

This document does not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation or maintenance.

The contents of this document are not part of an earlier or existing contract or agreement nor do they change this. The sales contract contains the entire obligation of Siemens. The warranty conditions specified in the contract between the parties is the sole warranty of Siemens. Any statements contained herein neither create new warranties nor modify the existing warranty.

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

The function manual enables the target group to configure and operate the SIMODRIVE 611 digital drive with hydraulic module.

If you have any questions, please contact the following hotline:

A&D Technical Support Tel.: [phone] – 222

Fax: [phone] – 223

E-Mail: mailto:[e-mail]

Internet: http://www.siemens.com/automation/support-request

Questions on the manual

If you have any questions (suggestions, corrections) regarding this documentation, please fax or e-mail us at:

	Fax: [phone] – 63315
	E-mail: mailto:[e-mail]
Fax form	Refer to the feedback sheet at the end of the documentation

Certificates	You will find the certificates for the products described in this documentation
	under:
	http://intra1.erlf.siemens.de/qm/home/index.html

♥ Siemens AG, 2006. All rights reserved	iii
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

Preface

1002..0399

Objectives

Information for using this manual

Definition of qualified personnel

Software version

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

SChapter 2 describes the procedures for configuring the electric and hydraulic components.

SChapter 3 shows how the hydraulic drive is started up with the support of a menu-driven user interface.

SThe firmware and the HLA module hardware functionality are explained in Chapters 4 and 5.

SChapter 6 explains how to check and interpret status displays and alarms (hydraulic diagnostics).

SChapter 7 describes the accessories required, e.g. measuring systems and cables.

SAppendix A contains general information and an explanation of the hydraulic system functionality.

Note

Hydraulics In this document, information about specific hydraulic functions refers to functions provided by Bosch Rexroth AG.

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

SGeneral table of contents

SHeader line (as orientation):

–The main chapter is in the upper header line

–The second line of the header is the subsection number

SAppendix with

–Abbreviations, Terms and List of References

–Index

For the purpose of this manual and product labels, a “qualified person” is one who is familiar with the installation, mounting, start-up and operation of the equipment and the hazards involved.

STrained and authorized to energize/de-energize, circuits and equipment in accordance with established safety procedures.

STrained in the proper care and use of protective equipment in accordance with established safety procedures.

SFirst aid training.

The SW versions specified in this documentation refer to the SINUMERIK 840D control system and the HLA module.

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

iv	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

1032.06993

Preface

Safety information/ instructions

This documentation contains information that must be observed to ensure your personal safety and to prevent material damage. The instructions for your personal safety are marked by a warning triangle. Instructions relating solely to material damage are not marked by a warning triangle. Depending on the degree of hazard, the warning information is shown as follows in decreasing sequence:

Danger

!indicates that death or severe personal injury will result if proper precautions are not taken.

Warning

!indicates that death or severe personal injury may result if proper precautions are not taken.

Caution

!With a warning triangle indicates that minor personal injury can result if proper precautions are not taken.

Caution

Without warning triangle indicates that material damage can result if proper precautions are not taken.

Notice

indicates that an undesirable result or state may arise if the relevant note is not observed.

Note

In the context of this document, it is advisable to take note of the warning information.

Intended use

Note the following:

Warning

!The unit may be used only for the applications described in the catalog and the technical description, and only in combination with the equipment, components and devices of other manufacturers where recommended or permitted by Siemens. To ensure trouble-free and safe operation of the product, it must be transported, stored and installed as intended and maintained and operated with care.

♥ Siemens AG, 2006. All rights reserved	v
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

Preface

100203..06993

Danger and warning information

Danger

!Commissioning should not start until you have ensured that the machine in which the components described here are to be installed complies with Directive 98/37/EC.

Only appropriately qualified personnel may commission/start up this equipment.

This personnel must take into account the technical customer documentation belonging to the product and be knowledgeable and observe the specified information and instructions on the hazards and warnings.

When electrical devices are operated, the electrical circuits automatically conduct a dangerous voltage.

Dangerous mechanical movements may occur in the system during operation.

All of the work carried-out on the electrical machine or system must be carried-out with it in a no-voltage condition.

Warning

!Perfect, safe and reliable operation of the equipment assumes that it has been professionally transported, stored, mounted and installed as well as carefully operated and serviced.

In addition to the danger and warning information provided in the technical customer documentation, applicable national, local, and system-specific regulations must be taken into account.

For special versions of the machines and equipment, the information in the associated catalogs and quotations applies.

!	Caution
	When attaching the connecting cables, you must ensure that:
	S They are not damaged,
	S	they are not stressed,
	S	they cannot come into contact with rotating parts.

Warning

!All of the SIMODRIVE unit connections must be withdrawn or disconnected when the electrical equipment on the machines is subject to a voltage test (EN 60204-1 (VDE 0113-1), Point 20.4).

This is necessary, as the SIMODRIVE insulation has already been tested, and should not be subject to a new test (additional voltage stressing).

vi	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

1032.06993

Preface

Warning

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

SFor special versions of the machines and equipment, the information in the associated catalogs and quotations applies.

SFurthermore, all of the relevant national, local land plant/system-specific regulations and specifications must be taken into account.

SAll work should be undertaken with the system in a no-voltage condition!

Caution

When using mobile radios (e.g. cellular phones, mobile phones, 2-way radios) with a transmission power of > 1 W close to the equipment (< 1.5 m) the function of the equipment can be disturbed.

Caution

As part of routine tests, the devices undergo a voltage test in accordance with EN 50178. During voltage testing of electrical equipment on industrial machines in accordance with EN 60204-1, Section 19.4, all SIMODRIVE device connections must be disconnected/removed. This is necessary in order to avoid damaging the SIMODRIVE devices.

♥ Siemens AG, 2006. All rights reserved	vii
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

Preface

1002..0399

ESDS information Electro Static Discharge Sensitive Devices and instructions

Some parts, such as individual components, integrated circuits or modules, could be damaged by electrostatic fields or electrostatic discharge during handling, testing or transport. These components are referred to as ESDS (ElectroStatic Discharge Sensitive Devices).

Handling ESDS modules:

SWhen handling devices which can be damaged by electrostatic discharge, personnel, workstations and packaging must be well grounded!

SElectronic components should only be touched when absolutely necessary.

SPersonnel may only touch components if

–they are continuously grounded through ESDS wristlets,

–they wear ESDS shoes, ESDS shoe grounding strips in conjunction with an ESDS floor surface.

SModules must only be placed on conductive surfaces (table with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

SModules may not be brought close to data terminals, monitors or television sets (minimum clearance to the screen > 10 cm).

SDo not bring ESD-sensitive modules into contact with chargeable and highly-insulating materials, such as plastic sheets, insulating table tops or clothing made of synthetic materials.

SMeasuring work may only be carried out on the components if

–the measuring instrument is properly grounded (e.g. equipment grounding conductor), or

–when floating measuring equipment is used, the probe is briefly discharged before making measurements (e.g. a bare-metal control housing is touched).

SOnly touch control components, option modules and memory modules at the front panel or at the edge of the PC boards.

J

viii	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

03.06

Table of Contents

1	General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1-13
	1.1	Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-13
	1.2	Comparison of electric and hydraulic drive systems . . . . . . . . . . . . .	1-14
	1.3	Structure of an electro-hydraulically controlled drive axis . . . . . . . .	1-16
	1.3.1	Machine commutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-16
	1.3.2	Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-17
	1.3.3	Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-17
	1.3.4	Valve amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-17
	1.3.5	Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-17
	1.3.6	Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-17
	1.3.7	SINUMERIK 840D/SIMODRIVE 611 digital . . . . . . . . . . . . . . . . . . . .	1-18
	1.3.8	Hydraulic power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-18
2	Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-19
	2.1	Configuring steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-19
	2.1.1	Procedure for configuring electrical components . . . . . . . . . . . . . . .	2-19
	2.1.2	Procedure for configuring hydraulic components . . . . . . . . . . . . . . .	2-20
	2.2	Integration in SINUMERIK 840D/SIMODRIVE 611 digital . . . . . . . .	2-22
	2.2.1	System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-22
	2.2.2	Required FW packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-27
	2.2.3	Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-27
	2.3	Configuring the hydraulic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-28
	2.3.1	Cylinder selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-28
	2.3.2	Selection of servo solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-30
	2.3.3	Selection of shut-off valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-37
	2.3.4	Natural frequency of the hydraulic drive . . . . . . . . . . . . . . . . . . . . . . .	2-40
	2.3.5	Hydraulic power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-41
	2.4	Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-43
	2.4.1	Internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-43
	2.4.2	External power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-43
	2.4.3	Grounding concept/electromagnetic compatibility (EMC) . . . . . . . .	2-46
3	Start-up .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-47
	3.1	Overview of start-up process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-47
	3.2	Drive configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-49
	3.3	Modify drive machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-50
	3.4	Valve selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-51
	3.5	Cylinder selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-54
	3.6	Mounting/supply data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-55
	3.7	Measuring system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-56
	3.8	Modifying data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-57
	3.9	Fine adjustment and optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-60

♥ Siemens AG, 2006. All rights reserved	ix
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

0302..0699

	3.9.1	Control direction, travel direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-60
	3.9.2	Offset adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-62
	3.9.3	Velocity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-63
	3.9.4	Referencing data for HLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-65
	3.9.5	Controller optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-66
	3.9.6	Controller adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-71
	3.9.7	Hydraulic/electrical interpolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-72
	3.10	File functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-73
	3.11	Start-up functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-74
	3.11.1	Measuring function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-75
	3.11.2	Function generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-82
	3.11.3	Circularity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-86
	3.11.4	Servo trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-86
	3.11.5	DAC parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-87
	3.12	User views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-88
	3.13	Display options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-89
	3.14	Configuring an OEM valve list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-90
	3.15	System variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-92
4	Firmware Drive Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4-93
	4.1	Block diagram of closed-loop control . . . . . . . . . . . . . . . . . . . . . . . . .	4-93
	4.2	Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-95
	4.2.1	Function overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-95
	4.2.2	Parameter set changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-96
	4.3	Closed-loop velocity control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-97
	4.3.1	Velocity adaptation/feedforward control . . . . . . . . . . . . . . . . . . . . . . .	4-97
	4.3.2	Velocity controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-104
	4.3.3	Dynamic stiffness control (DSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-112
	4.4	Closed-loop force control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-113
	4.4.1	Force limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-115
	4.4.2	Static friction injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-116
	4.4.3	Force controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-117
	4.5	Manipulated voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-122
	4.5.1	Characteristic compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-122
	4.5.2	Control output filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-128
	4.5.3	Manipulated voltage limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-130
	4.6	Supply unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-131
	4.7	Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-132
	4.8	Cylinder drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-134
	4.9	Drive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-135
	4.10	Position measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-138
	4.11	Pressure sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-143
	4.12	Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-144
	4.13	Monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-150

x	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

032.0699

	4.13.1	Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-150
	4.13.2	Variable signaling 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	Parameters table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-163
5	Hardware Drive Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		5-173
	5.1	Interface overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-173
	5.1.1	Measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-176
	5.1.2	Pressure sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-177
	5.1.3	Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-178
	5.1.4	Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-179
	5.1.5	Test sockets (diagnostics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-180
	5.1.6	Bus interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-181
	5.2	System environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-182
	5.3	Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-183
	5.3.1	Climatic and mechanical environmental conditions in operation . . .	5-183
	5.3.2	Shippingand storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-184
	5.3.3	Stress caused by contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-185
6	Hydraulics Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		6-187
7	Peripherals/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		7-217
	7.1	Measurement systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-217
	7.1.1	Encoders, linear scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-217
	7.1.2	Cable diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-220
	7.2	BERO (X432) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-224
	7.3	Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-225
	7.3.1	Sensor systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-225
	7.3.2	Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7-229
	7.4	Connection diagrams for servo solenoid valves . . . . . . . . . . . . . . . .	7-230
8	Servicing	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8-235
	8.1	Areas of responsibility at Siemens/Bosch Rexroth . . . . . . . . . . . . . .	8-235
	8.2	Hotline and contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8-236
A	Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		A-237
	A.1	Closed-loop proportional valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	A-237
	A.1.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	A-237
	A.1.2	Directly-controlled servo solenoid valves, sizes 6 and 10 . . . . . . . .	A-245
	A.1.3	Pilot-controlled servo solenoid valves, sizes 10 and 16 . . . . . . . . . .	A-247
	A.1.4	HR servo solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	A-250
	A.2	Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	A-252

♥ Siemens AG, 2006. All rights reserved	xi
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

0302..0699

B	Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		B-255
C	Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		C-257
D	References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		D-259
	D.1	Electrical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	D-259
	D.2	Hydraulic applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	D-259
E	EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		E-261
F	Index . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	Index-265

xii	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

General Information

1

1.1Application examples

Applications	The NCU 573.2 of the SINUMERIK 840D is capable of handling axis
	configurations of a maximum of 31 axes on up to 10 different channels. This
	functional sophistication makes the SINUMERIK 840D an increasingly popular
	system for the automation of rotary indexing machines. These machines are
	often highly compact in design and frequently equipped with hydraulic axes
	(cylinders and servo solenoid valves). The hydraulics module (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 control unit belonging to the modular SIMODRIVE 611
	converter system mounted in a 50 mm carrier module (universal empty hous-
	ing).
	The gating and closed-loop control electronics for operating controlled hydraulic
	drives are integrated in the HLA module.
	From the point of view of the manufacturer of modern servo solenoid valves, an
	innovative step in the field of hydraulic drive systems has been taken by treating
	electric and hydraulic drives as equally important components and integrating
	them into a standard NC.
Objective	Hydraulic and electric drives are equally important, and are also available for
	combinations within an interpolating grouping.

Interfaces

SFirmware

The communications -interface is compatible with SIMODRIVE 611 SRM(FD)/ARM(MSD) for supported services. Code and data structure is analogous to SIMODRIVE 611 SRM(FD)/ARM(MSD). The hydraulics software is stored as a separate program code in the control system.

SHardware

Integration into the SIMODRIVE 611 system is compatible with SIMODRIVE 611 digital SRM(FD)/ARM(MSD). Essentially, this involves the following interfaces:

–Drive bus

–Equipment bus

–Power supply concept

♥ Siemens AG, 2006. All rights reserved	1-13
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

1 General Information	1002..0399
1.2 Comparison of electric and hydraulic drive systems

1.2Comparison of electric and hydraulic drive systems

Table 1-1	Comparison of electric and hydraulic drive systems
Criterion			Direct electric drive		Electric drive with		Hydraulic drive
					leadscrew
Power density /		S Low weight and		S	Servo motor and	S Cylinder and servo sole-
mounting		S	reduced spatial re-		leadscrew large and		noid valve are light-weight
space require-					heavy.		and compact.
			quirements of the
ments					Problematic with lim-	S Transfer of E motor to hy-
			electric part on the	S
			machine table.		ited mounting space.		draulic power unit.
Mass inertia of		Low mass of electric part		Servomotor and leads-		Piston and piston rod have
moving parts		on machine table.		crew have high mass mo-		very low mass
				ment of inertia.
Operational		In principle, service life		S	Shock sensitive.	S	Protected against overload
safety, service		only depends		S	Service life limited by		by pressure limitation.
life		on the linear guides.
					leadscrew.	S	Sturdy, insensitive to
				S	Sudden failure		shocks.
					possible.	S Cylinder seals and valve
							control edges have a long
							service life.
						S	Wear warning.
Service		Simple replacement		Expensive replacement		S	Simple error diagnosis
				and repair of leadscrew by		S	Simple replacement and
				specialists.			repair of valves and cylin-
							ders.
Energy storage		Peak requirement must		Peak requirement must be		S	Compensation of energy
		be installed as no storage		installed as no storage is			requirement peaks by hy-
		is possible.		possible.			draulic accumulator.
						S Rapid traverse in differen-
							tial circuit.
						S Reduction of installed ca-
							pacity.
Maximum		Peak thrust per unit area		Limitation for high forces.		Practically unlimited
forces		approx. 40 to 80 kN/m2				(cylinder-φ, pmax=700 bar)
Load stiffness		Very good;		S	Elasticity under large	S Oil compressibility is com-
		Servo gain can be set			forces.		pensated as a control
		10–100 times higher than		S	Elasticity of leadscrew		function (I component).
		on the other two drives.
					is largely compen-	S Good zero overlap quality
					sated as a control		of valve ensures very high
					function.		rigidity under load.
Maximum ve-		Up to 500 m/min		vmax=hs @ ωmax/2π		30...300 m/min
locity				hs=thread lead		(depending on which cylinder
				ωmax=max. motor speed		seal kit is used)
Maximum		Unlimited		v 6 m		v 3 m
travel path
Collision		Mechanically difficult		Mechanically possible		Mechanically possible
protection

1-14	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

02.99									1 General Information
				1.2 Comparison of electric and hydraulic drive systems
Table 1-1	Comparison of electric and hydraulic drive systems
Criterion		Direct electric drive			Electric 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 of
									hydraulic power unit.
Acceleration		max. 45 g			max. 1 g				max. 2 g
characteristics
Drive cooling		Absolutely essential			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						–
			Velocity				Velocity
			Current				Flow rate
			DC link voltage				System pressure
			Power				Flow rate @ valve pressure differential
			Transistor/power section				Valve
			Motor				Drive cylinder

♥ Siemens AG, 2006. All rights reserved	1-15
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

1 General Information

02.99

1.3 Structure of an electro-hydraulically controlled drive axis

1.3Structure of an electro-hydraulically controlled drive axis

SINUMERIK 840D,
SIMODRIVE 611 digital
with HLA module	Servo solenoid value with
	valve amplifier (OBE)
	Machine commutation
Shut-off valve
	Position	measuring
Hydraulic power unit	system

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

1.3.1Machine commutation

Guide mechanism Straight line movement of machine slides and tables is accomplished with minimum friction and maximum precision by hydrodynamic and hydrostatic slideways or roller slideways.

Friction

A certain degree of friction can be very useful for damping oscillations.

However, excessive friction, especially pronounced transitions from static to sliding friction, has a negative effect on the control result and impairs control loop stability.

1-16	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

02.99	1 General Information
1.3	Structure of an electro-hydraulically controlled drive axis

1.3.2Cylinder

Construction	The cylinder represents the simplest form of a linear motor and can easily be
	integrated into machine guidance. The cylinder normally has a piston rod at one
	end.
Quality criteria	The following are critical quality criteria

Sthe surface quality of barrel and piston rod and

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

1.3.3Control valve

Task	This is the control element in the closed control loop system and forms the elec-
	tro-hydraulic converter.
Function	The valve steadily converts electrical signals into hydraulic flow.
	Its quality is defined by static and dynamic parameters, such as

Szero overlap

Shysteresis

Slimit frequency, etc.

1.3.4Valve 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) controls the position of the valve spool proportionally to the output value (U=0..."10 V).

1.3.5Shut-off valve

Shut-off valves are used to add safety functions to a valve control with servo solenoid valve. Shut-off valves can prevent uncontrolled motion of the cylinder.

1.3.6Position measuring system

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

♥ Siemens AG, 2006. All rights reserved	1-17
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

1 General Information	02.99
1.3 Structure of an electro-hydraulically controlled drive axis
Function	The velocity is acquired by continuous differentiation of the distance over time.
	Various systems are available depending on the level of accuracy required.

Highest accuracy requirements are achieved 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 approach at the beginning of a machining operation.

1.3.7SINUMERIK 840D/SIMODRIVE 611 digital

SINUMERIK control systems 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 control commands. It also monitors command execution continuously.

The control structures for the electro-hydraulic control loop and the interfaces to

Sthe shut-off valve,

Sthe servo solenoid valve,

Sthe position measuring system and

Sthe central processing 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 modules with graded scope of functions is provided to allow the SINUMERIK 840D NCU system to be tailored to a wide range of functional requirements of machines. This allows optimal adaptation to the machine and machining task, as well as allowing for equipping standardized machine series.

1.3.8Hydraulic power unit

This unit supplies hydraulic energy.

It is installed remotely from the drive axis. Accumulators are employed to compensate for strongly fluctuating hydraulic energy requirements and to minimize the installed power.

J

1-18	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

Configuration

2

2.1Configuring steps

2.1.1Procedure 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 encoder evaluation circuitry. This initial configuring phase may be followed by a second in some cases, in which the corresponding circuit recommendations and EMC measures are taken into account.

The functions of SIMODRIVE components are described with keywords in this

Planning Guide. Limit values for functions may be specified in some cases.

For further details (e.g. characteristics), please refer to the Installation and

Start-Up Guides for SIMODRIVE 611 digital and SINUMERIK 840 digital.

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

Phase 1

Selection of hydraulic

Section 2.3

components

and publication from Rexroth

Dimensioning of incoming

Section 2.2

mains supply

and publication 6SN1197-0AA00

Dimensioning of

Section 2.2

power modules

and publication 6SN1197-0AA00

Dimensioning of external

Section 2.4

power supply

Dimensioning of closed-

Chapter 4

loop control components

Dimensioning of position

Section 7.1

sensor (measuring system)

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

♥ Siemens AG, 2006. All rights reserved	2-19
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

2 Configuration	1002..0399
2.1 Configuring steps

Phase 2

Recommended circuits			Section 2.4
EMC measures

Block diagrams/		Section 2.2
connection diagrams

Abbreviations,

Appendix

terms and index

Fig. 2-2 2. Configuring phase

2.1.2Procedure for configuring hydraulic components

Hydraulically controlled drives are normally configured by the technical sales and marketing personnel of the hydraulics supplier (e.g. Bosch

Rexroth, see Chapter 8) in close co-operation with the machine manufacturer.

This configuring phase is divided into the following steps:

SSelection of the cylinder on the basis of forces and velocities required and the cylinder mounting conditions in the machine

(see Subsection 2.3.1).

SSelection of the servo solenoid valves on the basis of the cylinder data, forces, velocities and dynamic requirements (see Subsection 2.3.2, 2.3.3).

SSelection of the position measuring system and optionally the pressure sensors with regard to the measuring range, accuracy and linearity (see Section 7.1, 7.3).

SDimensioning of the hydraulic power unit, taking all loads into account (see Subsection 2.3.5).

SCalculation of the natural frequency of the drive for an initial assessment of whether the expected control result can be achieved (see Subsection 2.3.4).

SIn difficult cases, it may be worthwhile carrying out a dynamic simulation of the drive as an aid to configuration.

The basic data required to design a system are obtained from a questionnaire.

2-20	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

02.99	2 Configuration
	2.1 Configuring steps
Questionnaire	Design of hydraulic NC axes

	Hydraulic NC axes
	Design of systems with linear motions
Company:			Contact person:
Address:			Department:
			Phone:
Machine:
Axis:	Function/designation:
	Straight-cut control:		Continuous-path control:
Drive specification
Cylinder dimensions [mm]			Accuracy requirements
Piston diameter:			Positioning precision [ m]
1. rod diameter:			from rapid traverse:
2. rod diameter:			from feedrate:
Stroke:			Path accuracy:
Cylinder mounting position:			Velocity
			tolerance [mm/min]:
051-001/
Connection:			Position	incremental,
Valve cylinder			measuring system	output signal ...
Pipe/Hose length [mm]:			Make:
Pipe/Hose diameter [mm]:			Type:
Moved mass [kg]:			Other:
Machining forces [N]			Resolution [ m]:
Piston advance:
Piston retraction:
Slide guide friction			NC control system
	:		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:

♥ Siemens AG, 2006. All rights reserved	2-21
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

2 Configuration	02.99
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2.1System overview

Components	A complete SINUMERIK 840 digital control system with HLA module consists of
	various individual components. These are listed below.
	Table 2-1		Components of SINUMERIK 840 digital control with HLA module (number,
			component, description)
	No.		Component		Description
	in
	Fig.
	2-3
	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 unit and
					operator controls for NC
	D1)	MMC module		S	Operator panel calculator (integrated in panel),
				S MMC 103 with hard disk
	E	Mains supply module		Reference: /PJ1/ SIMODRIVE 611
		(MS)
	F1)	Machine control panel		S	Machine operation
	G11)	ISA adapter		S Allows AT modules to be used in conjunction with
					the MMC module MMC103 (mounted in operator
					panel)
	G2	Full keyboard for CNC		S	Full keyboard for connection to MMC module
	1)
	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 to	Cable		Reference: /Z/, Catalog of Accessories NC Z
	H 9
	H10	Cable		See Chapter 7, Peripherals/Accessories
	to
	H12
	I	SIMODRIVE hydraulic		S	Closed-loop control of hydraulic drive
		module (HLA module)
				S	Actuation of servo solenoid valve
		50 mm carrier module		Holder for HLA closed-loop control plug-in module
		(universal empty housing)		(see Fig. 2-6)
	I1	Phoenix cable connection		S	Shut-off valve
				S External 24 V supply
				S BERO input
				S “Power enable”
	J	SIMATIC components		Reference: /S7H/, Manual
	K	Terminator		Terminator for drive bus (inserted in last module in
				drive grouping)

2-22	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

0210.9903					2 Configuration
			2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital
	Table 2-1		Components of SINUMERIK 840 digital control with HLA module (number,
			component, description)
	No.		Component		Description
	in
	Fig.
	2-3
	L1)	Handheld unit		S	Connect HHU to K bus via MPI
				S Handwheel, EMERGENCY STOP button, key-ac-
					tuated switch, override, agreement buttons, dis-
					play, unassigned keys
	M1)	Distributor box		S	For linking the hand-held unit to the MPI bus
				S Connection for EMERGENCY STOP circuit, en-
					able keys, handwheel, 24 V DC
	N	Cable distributor		S	24V supply for connection to MPI connector
	O	Hydraulic drive		References:
				/BR1/, “Servo solenoid valves” catalog
					/BR2/, “Sensors and electronics” catalog
					/BR3/, “Adapter plate valves” catalog
	P	External 24 V supply		S	SITOP stabilized power supply modules
				Reference: SITOP catalog
				Order No. E860060-K2410-A101-A4

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 always be connected via a mains infeed module.

For information about connecting further additional SIMODRIVE monitoring modules in configurations with several HLA modules, please refer to the Planning Guide for SIMODRIVE 611 Converters /PJU/.

In a multi-tier configuration, all the infeed supply units must be connected simultaneously.

♥ Siemens AG, 2006. All rights reserved	2-23
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

2 Configuration

02.99

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

			Floppy
		G4
J		G1		MMC CPU	D
S7–300
					L
					C
H1					H5
		MCP			F
		H4
		G2
					H6
					M
E					(GND)
					H8
B
B1
		I1		O	N
G3			H10
		K
Device bus
A					Position sensing
		I
	MS	NCU HLA
		module	H11
			H12		Pressure sensor A
H2	Battery and plug-in fan				Pressure sensor B
	unit
H3
	Digital I/O
H9
	(high-speed NC I/O)
		Measure-			Servo solenoid
		ment (2x)
					valve
		Handwheel	BERO
		(2x) (1x of M)
			inputs
					Shutoff valve
SITOP power			Enable
(external PS)
P	External 26.5 V			Note:
	supply			Display of hydraulics for one axis

Fig. 2-3 System components

2-24	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

02.99

2 Configuration

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

Servo solenoid

Servo solenoid valve

valve

O

Pressure

Pressure sensor A

O

B

sensor A

Pressure sensor B

B

Pressure

sensor B

Position sensing

Position sensing

		Shutoff valve			Shutoff valve
		Hydraulic drive, axis 1		Hydraulic drive, axis 2
		Axis 1	HLA			Axis 2
	Position		–X101	–X102			Position
	measuring						measuring
	system					B	system
		B
		O	–X111	–X112		O
	Pressure sensor						Pressure sensor
	Servo solenoid		–X121	–X122			Servo solenoid
	valve						valve
		X431				X432
				–X35
			–X34
M	+	Functional ground			M	+	Functional ground1)
PV1		Shutoff valve, axis 1			PV2		Shutoff valve, axis 2
MV1	–	Reserved, do not use!			MV2	–	Reserved, do not use!
C1	+		X1141	X1341	C2
P24		External 26.5 V supply			B1		BERO input, axis 1
M24	–	Power enable at term. 663			19		Internal 0 V enabling voltage
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

♥ Siemens AG, 2006. All rights reserved	2-25
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

2 Configuration	02.99
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

	Relay contact,		NC	74
				73.1
			contact
	Ready to operate
				73.2
	message		NO
				72
			contact
	Relay contact for group message			5.3
				5.2
	I2t and motor overtemperature
				5.1
		Power disable		63
		Enabling voltage		9
		Enabling voltage		9
		Drive enable		64
	Reference potential for enable voltage			19
		P24		7
		P15		45
		N15		44
		N24		10
		M		15
		M		15
		RESET (R+term.15)		R
		Enabling voltage		9
		Setup mode		112
	Contactor energization, start			48
		Signaling contact,		111

	line contactor	213
		113
	Enabling signal for internal line contactor	NS1
		NS2
	Signaling contact for starting lockout (NC contact)	AS1
		AS2

DC link power supply for bridging line failures	M500
	P500
Electronics power supply from external source	2U1
Electronics power supply from external source	1U1
	2V1
	1V1
Electronics power supply from external source	2W1
	1W1

	LED displays
Electronics power	Red			Red	5 V voltage level
					fault
supply faulty
					Device ready
Device is not ready, Green
				Yellow (DC link
no enable signal					precharged)
(term. 63, 64 or 48)	Red			Red	DC link
Line fault
					overvoltage

X111

X121

X141

1)

X161

1)

X171

X172

LED displays

X351

X181

Device bus

1)

P600

DC link connection

M600

1) Jumpers inserted in delivery state	Power supply
	U1 V1 W1 X131 PE

Fig. 2-5 Interfaces on mains supply module (OI and I/RF module)

2-26	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

0210.9903

2 Configuration

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 (6SN1115–0BA11–0AA1)
Slotted screw
M3 / 0.8 Nm
	P600
	M600	M4 / 1.8 Nm
Order No.
	PE	Rating plate/Order No.
Slotted screw
	M5 / 3.0 Nm
M3 / 0.8 Nm

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

2.2.2Required FW packages

SSINUMERIK 840D NCK SW w5.1

incl. SIMODRIVE 611 digital HLA module w1.0

SSINUMERIK 840D MMC SW u5.1 or

SINUMERIK 840D HMI SW w6

2.2.3Hardware requirements

SNCU 561.2, 571.2, 572.2, 573.2

♥ Siemens AG, 2006. All rights reserved	2-27
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

2 Configuration	1002..0399
2.3 Configuring the hydraulic drive

2.3Configuring the hydraulic drive

General	Hydraulic drives are generally configured by technical sales personnel from the
information	hydraulics supplier, Rexroth.
	The configuration is based on the data from the questionnaire in Subsection
	2.1.2.
	Please refer to Appendix A for a description of hydraulic components.
	The hydraulic drive is configured in the sequence of steps described below.

2.3.1Cylinder selection

Piston and rod diameter

The piston and rod diameters are calculated according to Pascal’s theorem on the basis of the necessary compressive and tensile forces F and a standard pressure value of P=40...100 bar for machine tools (a maximum pressure 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
	Name					Diameter
Piston		25		32	40	50	63	80	100	125
Rod Standard		12		14	18	22	28	36	45	56
Rod Optional
		18		22	28	36	45	56	70	90

Stroke length	The stroke is identical to the working stroke of the drive except that it includes a
	few additional safety reserves.

2-28	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

0210.9903	2 Configuration
	2.3 Configuring the hydraulic drive
Mounting	In order to ensure good control quality, backlash-free mountings, e.g. base or
	flange mountings, must be used.

Flange mounting
Flange at front	Flange at rear
Base mounting

Fig. 2-7 Cylinder mounting methods

Mounting position This will depend on the machine’s situation and affects the choice of shut-off valves (see Subsection 2.3.3). Vertical loads must be protected via poppet valves. Forces due to weight must be taken into account in the final calculation of the operating pressure (MD 5151: CYLINDER_A_ORIENTATION).

	See Fig. 4.9 in Chapter 4-17 for the possible cylinder mounting positions.
Seal, friction	Suitable seals must be used to minimize friction. Transitions from static to slid-
	ing friction have a particularly adverse affect on the control result.
	The slide guide friction must be added to the cylinder friction. A friction com-
	pensation setting has been provided in the HLA module (MD 5460: FRIC-
	TION_COMP_GRADIENT) for the purpose of counteracting initial friction.
Cylinder pipes	The distance between the cylinder and servo solenoid valve must be kept as
	short as possible for the sake of the drive’s natural frequency (compressibility of
	the oil volume). In ideal cases, the servo solenoid valve is flange-mounted di-
	rectly on the cylinder.
Position	The incremental and absolute position measuring systems supported by the
measuring system	HLA module are mounted on the machine slide. It is also possible to use posi-
	tion measuring systems (SSI encoders) integrated in the cylinder.

♥ Siemens AG, 2006. All rights reserved	2-29
SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition

2 Configuration	1002..0399
2.3 Configuring the hydraulic drive

2.3.2Selection of servo solenoid valves

Reference: /BR1/, “Servo solenoid valves” catalog

Valve types (overview)

The HLA module supports servo solenoid valves with on-board electronics (OBE) supplied by Bosch Rexroth AG. The technical data for these valves and valves supplied by other manufacturers is stored in the HLA module software. The drive is parameterized automatically when the order number is entered. The following table lists the various types of servo solenoid valve and HR servo solenoid valves (HR = High Response) available from Bosch Rexroth AG.

For a complete list, please see Tables 2-4 to 2-10.

Table 2-3	Overview of servo solenoid and HR servo solenoid valves from Bosch Rexroth AG
	Description	Nomi-	Nominal flowrate (l/min)	Character-	Limit fre-
		nal	for nominal pressure drop	istic	quency
		size	per control edge (bar)		1)
					(Hz)
4WRPEH		6	up to 40 / 35 bar	linear and	110
(directly-controlled				with knee
servo solenoid valve)
		10	up to 100 / 35 bar	linear and	85
				with knee
4WRPE		10	up to 70 / 5 bar	with knee	40
(pilot-controlled servo
solenoid valve)
		16	up to 150 / 5 bar	with knee	40
4WRPEH		6	up to 40 / 35 bar	linear and	210
				with knee
(directly-controlled
HR servo solenoid valve)

4WRVE	10	up to 70 / 35 bar	with knee	80
(pilot-controlled
HR servo solenoid valve)

		16	up to 150 / 5 bar	with knee	80

1)The characteristic values specified for the valve limit frequencies relate to an amplitude of "5% and a phase offset in the Bode diagram of –90°, see also data in catalog supplied by Bosch Rexroth AG.

2-30	♥ Siemens AG, 2006. All rights reserved
	SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) – 03.06 Edition