Siemens SINUMERIK 840D Parts list manual

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

SINUMERIK
840D/810D/
FM-NC
SINUMERIK
Overview of SINUMERIK 840D/840Di/810D/FM-NC Documentation (04.00)
Brochure Catalog
Ordering Info
NC 60.1 *)
Technical Info.
NC 60.2
Description of
Functions
Drive Functions *)
Description of
Functions
-- Basic Machine *)
-- Extended Functions
-- Special Functions
SINUMERIK
611D
840D/810D
SINUMERIK
840D/840Di/
810D/
FM-NC
840D/840Di/
810D/
FM-NC/611
Accessories
Catalog
Accessories NC-Z
SINUMERIK
SIROTEC
SIMODRIVE
840D/840Di/
810D
FM-NC
611D
Lists *)
Installation &
Start-up Guide *)
-- F M - N C
-- 810D
-- 840D/611D
-- MMC
SINUMERIK
840D
Description of
Functions
Digitizing
SINUMERIK
SINUMERIK
840D/810D/
FM-NC
Configuring Kit
MMC 100/101
-- Configuring
Syntax
-- Development Kit
SINUMERIK
840D/810D/
FM-NC
Screen Kit
MMC 100/101
SW Update and
Configuration
SINUMERIK
840D/840Di/
810D/
FM-NC
SINUMERIK
840D/840Di/
810D
Operator
Components
(HW) *)
840D/840Di/
810D/
FM-NC
Description of
Functions
SINUMERIK
Safety Integrated
SINUMERIK
SIMODRIVE
SINUMERIK
840D/810D/
FM-NC
611,
Motors
SIMODRIVE
DOCONCD*)
The SINUMERIK System
General Documentation
Electronic Documentation
Manufacturer / Service Documentation
Manufacturer / Service Documentation
SINUMERIK
840D/810D/
FM-NC
SINUMERIK
840D/810D
User Documentation
Diagnostics
Guide *)
Operator’s Guide
-- Unit
Operator Panel
-- HPU
-- HT 6
AutoTurn
-- Short Guide
-- Programming (1)
-- S e t u p ( 2 )
SINUMERIK
840D/840Di/
810D/
FM-NC
Program. Guide
-- Short Guide
-- Fundamentals *)
-- Advanced *)
-- Cycles
-- Measuring Cycles
Description of
Functions
-- ManualTurn
-- ShopMill
Description of
Functions
Synchronized
Actions
Wood, Glass,
Ceramics
840D/810D
SINUMERIK
Operator’s Guide
-- ManualTurn
-- Short Guide ManualTurn
-- ShopMill
-- Short Guide ShopMill
840D/810D
Manufacturer / Service Documentation
SINUMERIK
840D/810D
Descr. of Functions
-- Computer Link
-- Tool Data
Information
System
*) These documents are a minimum requirement for the control
Operator’s Guide
-- Short Guide
-- Operator’s
Guide *)
SINUMERIK
840D/810D/
FM-NC
Configuring
(HW) *)
-- F M - N C
-- 810D
-- 840D
SINUMERIK
SINUMERIK
840D/810D
SINUMERIK
840D/810D/
FM-NC
Description of
Functions
Operator Interface
OP 030
Description of
Functions
Tool Manage-
ment
SINUMERIK
SIMODRIVE
SINUMERIK
SIMODRIVE
SINUMERIK
SIMODRIVE
SINUMERIK
SIMODRIVE
SINUMERIK
SIMODRIVE
840D
611D
840D
611D
Description of
Functions
Linear Motor
SINUMERIK
SIMODRIVE
SIROTEC
EMC
Guidelines
Description of
Functions
-- Hydraulics
Module
-- Analog Module
User Documentation
SINUMERIK
System Overview
840Di
Manufacturer / Service Documentation
SINUMERIK
Descr. of Functions
ISO Dialects for
SINUMERIK
840D/810D
SINUMERIK
Descr. of Functions
CAM Integration
DNC NT-2000
SINUMERIK
Manual
(HW + Installation
and Start-up)
840Di

Valid for
Control Software version
SINUMERIK 840D 5
SINUMERIK 840DE (export version) 5
04.00 Edition
SINUMERIK 840D
SIMODRIVE 611 digital
HLA module
Description of Functions
General 1
Configuring 2
Start-Up 3
Firmware Drive
Functions 4
Hardware Drive
Functions 5
Hydraulics Diagnostics 6
Peripherals/Accessories 7
Service 8
Hydraulics A
Abbreviations B
Definition of Terms C
References D
EC Declaration of
Conformity E
Index F

SINUMERIKDocumentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the ”Remarks”column.
Status code in the ”Remarks” column:
ANew documentation.. . . . .
BUnrevised reprint with new Order No.. . . . .
CRevised 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, SINUMERIKrund SIMODRIVErsind 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.
Further information is available on the Internet under:
http://www.ad.siemens.de/sinumerik
This publication was produced with Interleaf V 7.0.
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority. Offenders
will be liable for damages. All rights, including created by patent grant
or registration of a utility model or design, are reserved.
Siemens AG 2000. All rights reserved
Other functions not described in this documentation might be
executable in the control. However, no claim can be made regarding
the availability of these functions when the equipment is first supplied
or for service cases.
We have checked that the contents of this document correspond to
the hardware and software described. Nonetheless, differences might
exist and therefore we cannot guarantee that they are completely
identical. The information contained in this document is, however,
reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.
Subject to changes without prior notice.
Siemens AktiengesellschaftOrder No. 6SN1197–0AB60–0BP1
Printed in the Federal Republic of German
y
3ls

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Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
User information
The documentation for SIMODRIVE 611/SINUMERIK 840D is organized on the
following levels:
SGeneral documentation
SManufacturer/service documentation
SElectronic 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.
This documentation is intended for use by machine manufacturers and
servicing personnel who use “HLD modules”.
This Description of Functions provides the information required to configure and
start up the hydraulic drive module.
SChapter 2 describes the procedures to be followed to configure electrical
and hydraulic components.
SChapter 3 shows how the hydraulic drive is started up with the support of a
menu-assisted interface.
SFunctionalities provided by the firmware and the HLD module hardware are
explained in Chapters 4 and 5.
SChapter 6 explains how to check and interpret status displays and alarms
(hydraulics diagnostics).
SChapter 7 describes the accessories required, such as measuring system
and cables.
SAppendix 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.
Preface
Structure of the
documentation
Target group
Aim

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
Should further information be desired or should particular problems arise which
are not covered sufficiently for the purchaser’s purposes, the matter should be
referred to the local Siemens Sales Office.
The following guide information is provided to help you reference information in
this Description of Functions:
SGeneral table of contents
SHeader (as orientation aid):
–The top line of the header is the main section number
–The second line of the header is the subsection number
SAppendix with
–abbreviations, terms and references
–glossary (index)
If you require further explanation of a particular term, function or opera-
tion, you will find references to pages containing further relevant informa-
tion in the glossary.
For the purpose of this Description of Functions and product labels, a “qualified
person”is one who is familiar with the installation, mounting, start-up and opera-
tion of the equipment and the hazards involved. He or she must have the follow-
ing qualifications
STrained and authorized to energize, de-energize, ground and tag 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.
STrained in rendering first aid.
The SW versions specified in this documentation refer to the SINUMERIK 840D
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:
SSINUMERIK 840D control and SIMODRIVE 611 digital drive system,
software version 5
How to use this
manual
Definition:
How is a qualified
person defined?
Software
versions

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Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
!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.
Explanation of
symbols

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
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:
SThey must not be damaged
SThey must not be stressed
SThey 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.

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Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
!Warning
The information and instructions in all the documentation supplied and any
other instructions must always be observed to eliminate hazardous situations
and damage.
SThe information given in catalogs and quotations applies additionally to
special versions of machines and equipment.
SFurthermore, all relevant national, local and plant-specific regulations and
specifications must also be taken into account.
SAll work must be undertaken with the system in a no-voltage condition
(powered down!)

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
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:
SWhen handling components which can be destroyed by electrostatic di-
scharge, it must be ensured that personnel, the workstation and packaging
are well grounded,.
SAs a general rule, electronic boards should only be touched when absolu-
tely necessary.
SYou 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.
SBoards may only be placed on conductive surfaces (desk with ESDS sur-
face, conductive ESDS foam rubber, ESDS packing bag, ESDS transport
containers).
SBoards 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).
SBoards 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.
SMeasurements 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).
SClosed-loop control modules, option modules and memory submodules
may only be held by the front plate or on the board edges.
J
ESDS instructions

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Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00
Edition
Contents
1 General 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Examples of applications 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Comparison of electrical and hydraulic drive systems 1-16. . . . . . . . . .
1.3 Construction of an electro-hydraulically controlled drive axis 1-18. . . .
1.3.1 Machine guideway 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Cylinders 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Servo solenoid valve 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.4 Valve amplifier 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.5 Shutoff valve 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.6 Position measuring system 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital 1-20. . . . . . . . . . . . . . . . . . .
1.3.8 Hydraulic power unit 1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Configuring 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Configuring steps 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Procedure for configuring electrical components 2-21. . . . . . . . . . . . . . .
2.1.2 Procedure for configuring hydraulic components 2-22. . . . . . . . . . . . . . .
2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital 2-24. . . . . . .
2.2.1 System overview 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2 Required FW packages 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3 Hardware requirements 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Configuring the hydraulic drive 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Cylinder selection 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Selection of servo solenoid valves 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Selection of shutoff valves 2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Natural frequency of hydraulic drive 2-42. . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5 Hydraulic power unit 2-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Wiring 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Internal power supply 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 External power supply 2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Earthing system/electromagnetic compatibility (EMC) 2-49. . . . . . . . . .
3 Start-Up 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Overview of start-up process 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Drive configuration 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Drive machine data 3-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Valve selection 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1 General 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Cylinder selection 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Mounting/supply data 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Measuring system data 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Changing data 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04.00

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
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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Edition
4.13.2 Variable signalling functions 4-152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Service functions 4-157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14.1 Min/max display 4-157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14.2 Monitor 4-158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14.3 Diagnostic machine data 4-159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Table of parameters 4-163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Hardware Drive Functions 5-173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Overview of interfaces 5-174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Measuring system 5-176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2 Pressure sensors 5-177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3 Servo solenoid valve 5-178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.4 Terminals 5-179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.5 Test sockets (diagnosis) 5-180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.6 Bus interfaces 5-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 System environment 5-182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Additional information 5-183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Climatic and mechanical environmental conditions in operation 5-183. .
5.3.2 Shipment and storage conditions 5-184. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3 Resistance to pollutants 5-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Hydraulics Diagnostics 6-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Peripherals/Accessories 7-215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Measuring systems 7-215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Encoders, linear scales 7-215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2 Connection diagrams 7-218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 BERO (X432) 7-221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Pressure sensing 7-222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Sensors 7-222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Connection diagrams 7-226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Connection diagrams for servo solenoid valves 7-227. . . . . . . . . . . . . . . .
8 Service 8-231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Areas of responsibility of Siemens and Bosch 8-231. . . . . . . . . . . . . . . . .
8.2 Hotline 8-232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Hydraulics A-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Servo solenoid valves A-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.1 General A-233. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.2 Servo solenoid valves of sizes 6 and 10 A-242. . . . . . . . . . . . . . . . . . . . . .
A.1.3 Pilot-actuated sizes 10 and 16 servo solenoid valves A-244. . . . . . . . . . .
A.1.4 HRV valves A-247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Cylinder A-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04.00

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
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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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
General
1.1 Examples of applications
The NCU 573.2 of the SINUMERIK 840D is capable of handling axis
configurations of a maximum of 31 axes in up to 10 different channels. 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.
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.
SFirmware
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.
SHardware
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
Examples of
applications
Objective
Interfaces
1

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1-16 Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
1.2 Comparison of electrical and hydraulic drive systems
Table 1-1 Comparison of electrical and hydraulic drive systems
Criterion Electrical direct drive Electrical drive with
leadscrew
Hydraulic drive
Power density /
mounting
space require-
ments
SElectrical part on
machine table
Sis light and requires
little space.
SServomotor and lead-
screw large and
heavy.
SProblematic with lim-
ited mounting space.
SCylinder and servo sole-
noid valve are light-weight
and compact.
STransfer of E motor to
hydraulic power unit.
Mass inertia of
moving parts
Electrical part on
machine table has low
mass.
Servomotor and lead-
screw have high mass
moment of inertia.
Piston and piston rod have
very low mass
Operational
reliability, ser-
vice life
Service life depends in
principle only on linear
guides.
SShock-sensitive.
SService life limited by
leadscrew.
SSudden failure
possible.
SProtected against overload
by pressure limitation.
SSturdy, insensitive to
shocks.
SCylinder seals and valve
control edges have long
service life.
SWarning of wear.
Servicing Simple replacement Expensive replacement
and repair of leadscrew by
specialists.
SSimple error diagnosis
SSimple replacement and
repair of valves and cylin-
ders.
Energy storage Peak requirement must
be installed as no storage
possible.
Peak requirement must be
installed as no storage
possible.
SCompensation of energy
requirement peaks by hy-
draulic accumulator.
SRapid traverse in differen-
tial circuit.
SReduction of installed ca-
pacity.
Maximum
forces
Peak thrust per unit area
approx. 40 to 80 kN/m2Restriction with larger forces.
Practically unlimited (6MN)
(Cylinder φ, pmax=315 bar)
Load stiffness Very good;
Servo gain can be set to
betw. 10–100 times
higher than on the other
two drives.
SElasticity under large
forces.
SElasticity of leadscrew
is largely compen-
sated as a control
function.
SOil compressibility is com-
pensated as a control
function (I component).
SGood zero overlap quality
of valve ensures very high
rigidity under load.
Maximum
velocity
Up to 500 m/min vmax=hsωmax/2π
hs=thread lead
ωmax=max. motor speed
120 m/min
with standard servo-cylinder
Maximum
travel path
Unlimited 6 m 1 m
Collision
protection
Mechanically difficult Mechanically possible Mechanically possible
1 General
1.2 Comparison of electrical and h
y
draulic drive s
y
stems

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Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
Table 1-1 Comparison of electrical and hydraulic drive systems
Criterion Hydraulic driveElectrical drive with
leadscrew
Electrical direct drive
Noise Noise produced by
linear guides
Noise produced by servo-
motor and leadscrew SFlow through valve may
produce noise.
SPump noise on
hydraulic power unit.
Acceleration
characteristics
Max. 45 g Max. 1 g Max. 2 g
Drive cooling Mandatory Required only at high
speeds
Required in some cases, in
power unit only
Sensitivity to
ferromagnetic
swarf
High Low Low
Table 1-2 Analogy of characteristic data
Electrical Hydraulic
Speed –
Speed Speed
Current flow
DC link voltage System pressure
Power Flowrate Valve pressure difference
Transistor/power section Valve
motor Drive cylinder
1 General
1.2 Comparison of electrical and h
y
draulic drive s
y
stems

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1-18 Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
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
Position measuring
system
Hydraulic power unit
Shutoff valve
Fig. 1-1 Construction of an electro-hydraulically controlled drive axis
1.3.1 Machine guideway
Hydrodynamic and hydrostatic sliding or roller guides allow rectilinear motion
of machine slides and tables to take place with minimum friction and maximum
precision.
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.
Guide mechanism
Friction
1 General
1.3 Construction of an electro-h
y
draulicall
y
controlled drive axis

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Siemens AG 2000. All rights reserved
SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
1.3.2 Cylinders
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.
The following are critical quality criteria:
SThe surface quality of barrel and piston rod and
SThe seals and guides (low-friction, servo quality...).
1.3.3 Servo solenoid valve
This is the final control element in the closed control loop and forms the electro-
hydraulic converter.
The valve steplessly converts electrical signals into a hydraulic flow.
Its quality is defined by static and dynamic parameters, such as
Szero overlap
SHysteresis
Slimit 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
The position measuring system supplies the actual value for the position of the
moving machine element.
Construction
Quality criteria
Task
Function
Task
1 General
1.3 Construction of an electro-h
y
draulicall
y
controlled drive axis

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SINUMERIK 840D/SIMODRIVE 611 digital Descr. of Functions HLA Module (FBHLA) –04.00 Edition
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
Sthe shutoff valve,
Sthe servo solenoid valve,
Sthe position measuring system and
Sthe 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
Function
1 General
1.3 Construction of an electro-h
y
draulicall
y
controlled drive axis