Application software for servo-variable pump drives (SvP) p/q control

Transcription

1 Application software for servo-variable pump drives (SvP) p/q control S00V02R33 (Standard) S02V01R06 (Advanced) RE AW/06.10 Replaces: English Application description

2 The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging. This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. The cover page shows an example configuration. The original application description was prepared in German language.

3 RE AW/06.10 Application description Bosch Rexroth AG 3/100 Contents Contents 1 About this document Validity of the instructions Related documentation Illustration of information Principal safety instructions General information on this chapter Intended use Improper use Qualification of personnel General safety instructions Product- and technology-related safety instructions Scope of delivery Information on this product Introduction Main features Component overview Identification of software and parameter set Transport and storage Transporting software Operating instructions for "IndraWorks Ds" Functional description Modes of operation Command management Motor fan control Double pump selection Master-slave operation Leakage compensation Input signal via fieldbus bus system Automatic offset correction Parameter adjustment Application controller Inputs / outputs Installation Required tools Required accessories SvP controller assembly Parameter Commissioning Software components upload Checking the hardware settings Commissioning of the application software Troubleshooting Fault finding procedure Diagnostic messages and function Description of the application-specific errors and warnings Appendix... 89

4 4/100 Bosch Rexroth AG Application description RE AW/06.10 Contents 12.1 Wiring diagrams Service and support Service and support form Alphabetical index...97

5 RE AW/06.10 Application description Bosch Rexroth AG 5/100 About this document 1 About this document These instructions contain important information on the safe and appropriate commissioning, operation and simple troubleshooting of the application software for servo-variable pump drives (SvP). It aims at users and operators. Read these instructions completely, especially chapter 2 "Principal safety instructions" on page 11 before working with the application software SvP. 1.1 Validity of the instructions These instructions apply to the following products: Application software SvP with standard performance Table 1: Standard performance material number Material description FWS-MLDTFA-SVP-02VRS-NN-IMM-24S FWS-MLDTFA-SVP-02VRS-NN-IMM-24S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-24H FWS-MLDTFA-SVP-02VRS-NN-IMM-24H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-33S FWS-MLDTFA-SVP-02VRS-NN-IMM-33S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-33H FWS-MLDTFA-SVP-02VRS-NN-IMM-33E FWS-MLDTFA-SVP-02VRS-NN-IMM-33H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-48S FWS-MLDTFA-SVP-02VRS-NN-IMM-48S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-48H FWS-MLDTFA-SVP-02VRS-NN-IMM-48E FWS-MLDTFA-SVP-02VRS-NN-IMM-48H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-60S FWS-MLDTFA-SVP-02VRS-NN-IMM-60S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-60H FWS-MLDTFA-SVP-02VRS-NN-IMM-60E FWS-MLDTFA-SVP-02VRS-NN-IMM-60H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-75S FWS-MLDTFA-SVP-02VRS-NN-IMM-75S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-75H FWS-MLDTFA-SVP-02VRS-NN-IMM-75E FWS-MLDTFA-SVP-02VRS-NN-IMM-75H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-100S FWS-MLDTFA-SVP-02VRS-NN-IMM-100S2 Material number R R R R R R R R R R R R R R R R R R R R R R R R R R

6 6/100 Bosch Rexroth AG Application description RE AW/06.10 About this document Material description FWS-MLDTFA-SVP-02VRS-NN-IMM-100H FWS-MLDTFA-SVP-02VRS-NN-IMM-100E FWS-MLDTFA-SVP-02VRS-NN-IMM-100H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-120S FWS-MLDTFA-SVP-02VRS-NN-IMM-120S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-120H FWS-MLDTFA-SVP-02VRS-NN-IMM-120E FWS-MLDTFA-SVP-02VRS-NN-IMM-120H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-150S FWS-MLDTFA-SVP-02VRS-NN-IMM-150S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-150H FWS-MLDTFA-SVP-02VRS-NN-IMM-150E FWS-MLDTFA-SVP-02VRS-NN-IMM-150H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-190S FWS-MLDTFA-SVP-02VRS-NN-IMM-190S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-190E FWS-MLDTFA-SVP-02VRS-NN-IMM-190H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-240S2 FWS-MLDTFA-SVP-02VRS-NN-IMM-240H2 FWS-MLDTFA-SVP-02VRS-NN-IMM-300S2 Material number R R R R R R R R R R R R R R R R R R R R Application software SvP with advanced performance Table 2: Advanced performance material number Material description FWS-MLDTFA-SVP-12VRS-NN-IMM-24S FWS-MLDTFA-SVP-12VRS-NN-IMM-24S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-24H FWS-MLDTFA-SVP-12VRS-NN-IMM-24H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-33S FWS-MLDTFA-SVP-12VRS-NN-IMM-33S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-33H FWS-MLDTFA-SVP-12VRS-NN-IMM-33E FWS-MLDTFA-SVP-12VRS-NN-IMM-33H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-48S FWS-MLDTFA-SVP-12VRS-NN-IMM-48S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-48H FWS-MLDTFA-SVP-12VRS-NN-IMM-48E FWS-MLDTFA-SVP-12VRS-NN-IMM-48H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-60S Material number R R R R R R R R R R R R R R R

7 RE AW/06.10 Application description Bosch Rexroth AG 7/100 About this document Material description FWS-MLDTFA-SVP-12VRS-NN-IMM-60S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-60H FWS-MLDTFA-SVP-12VRS-NN-IMM-60E FWS-MLDTFA-SVP-12VRS-NN-IMM-60H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-75S FWS-MLDTFA-SVP-12VRS-NN-IMM-75S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-75H FWS-MLDTFA-SVP-12VRS-NN-IMM-75E FWS-MLDTFA-SVP-12VRS-NN-IMM-75H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-100S FWS-MLDTFA-SVP-12VRS-NN-IMM-100S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-100H FWS-MLDTFA-SVP-12VRS-NN-IMM-100E FWS-MLDTFA-SVP-12VRS-NN-IMM-100H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-120S FWS-MLDTFA-SVP-12VRS-NN-IMM-120S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-120H FWS-MLDTFA-SVP-12VRS-NN-IMM-120E FWS-MLDTFA-SVP-12VRS-NN-IMM-120H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-150S FWS-MLDTFA-SVP-12VRS-NN-IMM-150S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-150H FWS-MLDTFA-SVP-12VRS-NN-IMM-150E FWS-MLDTFA-SVP-12VRS-NN-IMM-150H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-190S FWS-MLDTFA-SVP-12VRS-NN-IMM-190S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-190E FWS-MLDTFA-SVP-12VRS-NN-IMM-190H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-240S2 FWS-MLDTFA-SVP-12VRS-NN-IMM-240H2 FWS-MLDTFA-SVP-12VRS-NN-IMM-300S2 Material number R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R

8 8/100 Bosch Rexroth AG Application description RE AW/06.10 About this document 1.2 Related documentation The following related documents must be observed for operation and commissioning: R /EN: Rexroth IndraDrive Drive Controllers Power Sections HCS02 (Instruction manual) R /EN: Rexroth IndraDrive Drive Controllers Power Sections HCS03 (Instruction manual) R /EN: Rexroth IndraDrive Drive Systems With HMV01/02 HMS01/02, HMD01, HCS02/03 (Project planning manual) R /EN: Rexroth IndraDrive C Supply Units and Power Sections (Project planning manual) R /EN: Rexroth IndraDrive C Drive Controllers Control Sections (Project planning manual) R /EN: Rexroth IndraDrive C Drive Controllers HCS02.1, HCS03.1 (Operating instructions) R /EN: Rexroth IndraDrive Drive Controllers HCS04.2E (Project planning manual) R /EN: Rexroth IndraDrive Firmware for Drive Controllers MPH- 05, MPB-05, MPD-05 (Functional description) R /EN: Rexroth IndraDrive Firmware for Drive Controllers MPH-, MPB-, MPD-, MPC-07 (Functional description) R /EN: Rexroth IndraDrive C Drive Controllers MPx-02 to MPx- 07 (Parameter description) R /EN: Rexroth IndraDrive MPx-02 to MPx-07 and HMV (Troubleshooting guide) R /EN: Rexroth IndraDyn S MSK Synchronous Motors (Project planning manual) RE30269: Pressure transducer with integrated electronics Type HM17 (Data sheet) 1.3 Illustration of information Consistent safety instructions, symbols, terms and abbreviations are used so that you can quickly and safely work with your product using this manual. For a better understanding, they are explained in the following sections Safety instructions In this manual, safety instructions are indicated whenever sequences of operations are explained which bear the risk of personal injury or damage to property. The measures described for preventing these hazards must be observed. Safety instructions are set out as follows: SIGNAL WORD! Type of risk Consequences in case of non-compliance Precaution Warning sign: Draws attention to the danger Signal word: Identifies the degree of danger Type of risk: Specifies the type or source of danger Consequences: Describes the consequences of non-compliance Precautions: Specifies how the danger can be prevented

9 RE AW/06.10 Application description Bosch Rexroth AG 9/100 About this document Table 3: Risk classes according to ANSI Z Signal word Application DANGER! Indicates an imminently hazardous situation which, if not avoided, will certainly result in death or serious injury. WARNING! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION! Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to equipment. NOTE Indicates damage to property: The product or the environment could be damaged Symbols The following symbols indicate notes which are not safety-relevant but increase the understanding of the documentation. Table 4: Meaning of the symbols Symbol Meaning If this information is not observed, the product cannot be used and/or operated optimally. individual, self-dependent step numbered instruction: The numbers indicate that the steps must be carried out one after the other.

10 10/100 Bosch Rexroth AG Application description RE AW/06.10 About this document Abbreviations used The following abbreviations are used in this documentation: Table 5: Abbreviations Abbreviation Meaning Dr AC DR AU ro CCM H HW KP L MLD MMC M/S n OM p PC PM PWM Q PLC SvP TN TV Drive is ready Alternating Current Drive Release Automatic Mode Ready for operation Control communication High Hardware Pressure control gain factor Low Motion Logic Device Multimedia Card Master-Slave Speed Online Mode Pressure Personal Computer Parameter Mode Pulse Width Modulation Flow Programmable Logic Control Servovariabler Pumpenantrieb (deu) Servo-variable Pump Drive (eng) Reset time of pressure control Derivative time of pressure control

11 RE AW/06.10 Application description Bosch Rexroth AG 11/100 Principal safety instructions 2 Principal safety instructions 2.1 General information on this chapter The product has been manufactured according to the accepted rules of current technology. However, there is still the risk of personal injury and damage to property if you do not observe this chapter and the safety instructions in this documentation. Read this documentation completely and thoroughly before working with the product. Keep this documentation in a location where it is accessible to all users at all times. Always include the required documentation when you pass the product on to third parties. 2.2 Intended use The product is an application software with related parameter set. Application software and parameter set are optimized for the operation of servo-variable pump drives in p/q control. They may only be used for applications in this area. In this connection, the overall system must satisfy the relevant applicable standards and directives. The application software is not suitable for performing safetyrelevant functions. It cannot be guaranteed that the software is free from defects. During its operation, you must therefore take suitable measures in order to avoid and/or minimize the consequences of defects according to the notes in this document. Standard performance Advanced performance The application software of the standard performance may only be operated in connection with the control section CSH01.1C and the firmware FWA-INDRV*-MPH-05VRS-D5-1-NNN-MP, material number: R (suitable for technology functions), and exclusively with the corresponding components of the hardware sets for the application of servo-variable pump drives. The application software of the advanced performance may only be operated in connection with the control section CSH01.3C and the firmware FWA-INDRV*-MPC-07VRS-D5-1-NNN-MP, material number: R (suitable for technology functions) and exclusively with the corresponding components of the hardware sets for the application of servo-variable pump drives. The admissible hardware sets for the standard performance and advanced performance of the application software are shown in Table 6:. The assignment to the relevant software versions is contained in chapter 1.1 "Validity of the instructions".

12 12/100 Bosch Rexroth AG Application description RE AW/06.10 Principal safety instructions Table 6: Admissible hardware sets for SvP Flow [l/min] Economy Standard Hardware sets divided into power stages Standard 200 High performance High performance S 24S2 24H 24H E 33S 33S2 33H 33H E 48S 48S2 48H 48H E 60S 60S2 60H 60H E 75S 75S2 75H 75H E 100S 100S2 100H 100H E 120S 120S2 120H 120H E 150S 150S2 150H 150H E 190S 190S H S H S NOTE Incorrect parameters Damages to the components of the drive as well as the machine due to incorrect command and actual values incorrect increase times of pressure and speed incorrect closed-loop speed control incorrect actuating signal to the electric drive Incorrect machine function (e.g. pressure too high, pressure too low, negative rotation of the hydraulic displacer and cavitation) Check the correct parameter setting directly after entering it into the system. An application-specific adjustment of the parameters within the scope of the initial commissioning is admissible. The transfer of application software and related parameters by means of MMC to the hardware specified above for the purpose of updating an already existing application software and/ the admissible parameters is permitted. The product is intended for the professional use and not for private use. Intended use includes having read and understood these instructions, especially chapter 2 "Principal safety instructions". The present documentation describes the function of the application software.

13 RE AW/06.10 Application description Bosch Rexroth AG 13/100 Principal safety instructions 2.3 Improper use Any use deviating from the intended use is improper and thus not admissible. Bosch Rexroth AG does not assume any liability for damage caused by improper use. The user assumes all risks involved with improper use. 2.4 Qualification of personnel The activities described in this documentation require basic knowledge of electrics and hydraulics as well as knowledge of the appropriate technical terms. In order to ensure safe use, these activities may only be carried out by a corresponding expert or an instructed person under the direction and supervision of an expert. Experts are those who can recognize potential hazards and apply the appropriate safety measures due to their professional training, knowledge and experience, as well as their understanding of the relevant conditions pertaining to the work to be undertaken. An expert must observe the relevant specific professional rules. The following is required as additional qualification: Knowledge of the wiring of the components: see documentation on the electrical components (chapter 1.2 "Related documentation") Knowledge of the commissioning of the application software and adjustment of the parameters Basic control engineering knowledge 2.5 General safety instructions Observe the valid regulations on accident prevention and for environmental protection. Observe the safety regulations and provisions of the country where the product is implemented/used. Exclusively use Rexroth products in good technical order and condition. Observe all notes on the product as well as the corresponding documents. Persons who assemble, operate, disassemble or maintain Rexroth products must not consume any alcohol, drugs or pharmaceuticals that may affect their ability to respond. Only use accessories and spare parts authorized by the manufacturer. Comply with the technical data and environmental conditions indicated in the product documentation. The installation or use of inappropriate products in safety-relevant applications could result in uncontrolled operating conditions when being used which in turn could cause injuries and/or damages to property. Therefore please only use a product for safety-relevant applications if this use is expressly specified and permitted in the documentation of the product. The application software is not suitable for performing safety-relevant functions. Do not commission the product until you can be sure that the end product (for example a machine or system) where the Rexroth product is installed complies with the country-specific provisions, safety regulations and standards of the application.

14 14/100 Bosch Rexroth AG Application description RE AW/06.10 Principal safety instructions 2.6 Product- and technology-related safety instructions The application software SvP cannot be used for the mapping of safety-relevant functions. Suitable measures for the protection of the installation and persons have to be provided by the system. NOTE Error in the application software The following situations may occur on the machine: Increased material waste Increased standstill times Damage to or destruction of the SvP drive unit Damage to or destruction of the tool Check the parameters before commissioning the machine for the first time and ensure that the correct parameter set for the application software is loaded. Moreover absorb possible consequences by system-internal measures. NOTE Uncontrolled movement of the SvP The system or individual components may be damaged. Always parameterize the analog inputs correctly and carefully according to the following description. NOTE Limited error detection of hardware defects The error detection of hardware defects can only be performed restrictedly. Further error cases are not supervised (e.g. parasitic coupling, defective fans, cable break with incorrect values in the valid value range, etc.). incorrect command and actual values incorrect increase times of pressure and speed incorrect closed-loop speed control incorrect actuating signal to the electric drive Incorrect machine function (e.g. pressure too high, pressure too low, negative rotation of the hydraulic displacer and cavitation) Perform additional supervisions on the system side according to chapters to Moreover absorb possible consequences by system-internal measures.

15 RE AW/06.10 Application description Bosch Rexroth AG 15/100 Principal safety instructions NOTE Incorrect parameterization, missing protection of the parameters against unauthorized access, and missing parameter validation Damages to the components of the drive as well as the machine due to incorrect command and actual values incorrect increase times of pressure and speed incorrect closed-loop speed control incorrect actuating signal to the electric drive Incorrect machine function (e.g. pressure too high, pressure too low, negative rotation of the hydraulic displacer and cavitation) Store the set parameters in a back-up copy. Perform the parameterization according to the limits and specifications contained in this document. Only allow trained and skilled staff to perform parameterization. Check the parameters before commissioning the machine for the first time and ensure that the correct parameter set for the application software is loaded. NOTE Missing validation of closed-loop control and error monitoring by redundant software or hardware structure Damages to the components of the drive as well as the machine due to incorrect command and actual values incorrect increase times of pressure and speed incorrect closed-loop speed control incorrect actuating signal to the electric drive Incorrect machine function (e.g. pressure too high, pressure too low, negative rotation of the hydraulic displacer and cavitation) Perform additional supervisions on the system side. Do not perform any safety-relevant functions with the application software.

16 16/100 Bosch Rexroth AG Application description RE AW/06.10 Scope of delivery 3 Scope of delivery The scope of delivery includes: Application software incl. related parameter set on MMC Firmware depending on the application software on MMC Application description The application software and the related parameter set are delivered together with a control section according to the hardware set in Table 6:. 4 Information on this product 4.1 Introduction This document describes the functionality of the application software for the application in a servo-variable pump drive. With this application software, extended functionalities for drive controllers of the "Rexroth IndraDrive" product family are provided. The extended function must be adjusted to the installation in which it will be used (configuration and parameterization). 4.2 Main features Servo-variable pump drives (SvP) largely satisfy the increasing requirements of the market regarding the reduction in noise emission and the increase in energy efficiency. The energy losses occurring with conventional hydraulic power units in partial load operation are reduced by shifting the pressure and displacement control to the electrical drive side. Depending on the required pressure and flow, the speed of the electric motor is selected so that the corresponding output parameters are set. A variable-speed pump drive mainly consists of electric motor, hydraulic pump and a drive controller of the "Rexroth IndraDrive" product family with a specially adjusted application software. In the version with pressure control, you moreover need a pressure transducer. With the project planning program "IndraWorks Ds", the users can adjust the speed-variable pump system to their application by parameterizing the drive controller and the application software. After completed system configuration, the speed-variable pump drive is controlled by thee existing analog and digital inputs and outputs and/or the fieldbus bus system.

17 RE AW/06.10 Application description Bosch Rexroth AG 17/100 Information on this product Fig. 1: Basic structure of a speed-variable pump system Control section Power section Application software The drive controllers of the IndraDrive device family consist of a control section and a power section. The control section can be adjusted to the hardware of an application using socalled option modules. The control section also accommodates the main processor which completely controls the drive controller. The "IndraDrive" device family accommodates several classes of control sections which differ in the fitting of the option modules as well as in their individual performance. Due to the higher performance of the main processor and the high variability with regard to the fitting with option modules, only advanced control sections are used. For the application of standard performance, CSH01.1C series control sections are used, and for advanced performance, CSH01.3C series control sections are used. The power section basically contains the power components that are required for controlling the synchronous servo motor. The size of the power section depends on the performance class of the motor. Power sections of type HCS02 or HCS03 are used. The application software is part of the "IndraMotion MLD", the so-called soft PLC or drive-internal PLC. The MLD is part of the firmware of the drive-internal control. The firmware of the drive controller contains all software functions that are necessary for controlling an AC drive motor.

18 18/100 Bosch Rexroth AG Application description RE AW/06.10 Information on this product The application software for SvP is available in two variants, the so-called standard performance and advanced performance. The difference of these two variants is the velocity with which the speed provision is implemented at the drive. Pressure control is identical for both systems. The standard performance application software is optimized and authorized for the use with the MPH05VRS firmware, while the MPC07VRS firmware must be used for the advanced performance. As already explained above, the selection of the performance level function incorporates the selection of another control section. An overview of the control sections is provided in chapter 4.3 "Component overview". As for the advanced performance, other firmware is used as well, in particular MPC07VRS, the L2 safety modules (start interlock) and the safety system (S2) are supported. Both application solutions, standard and advanced, otherwise have the same scope of functions and are operated equally. The following figure is a graphical presentation of the basic connection of the hardware and software assemblies of the drive controller. Drive controller AC supply HCS02 or HCS03 power section CSH01.1C/CSH01.3C control section 3~ MPH05VRS/MPC07VRS firmware = Communication interface IndraMotion MLD Application- software Operating state control Parameter handling Device control Analog and digital signals Enable pcommand pactual ncommand (Q command ) nactual (Qactual) IO mapping Signal processing Application controller (e.g. p/q controller) Diagnosis Motor fan controller Position, speed and flow controller Device and error status M Fig. 2: Overview of set-up and structure of the drive controller

19 RE AW/06.10 Application description Bosch Rexroth AG 19/100 Information on this product 4.3 Component overview In this chapter, you will find an overview of the permissible components. Hardware components The following hardware components are necessary: Power section Rexroth "IndraDrive C" converter HCS02 or HCS03 (standard and advanced performance) HCS04 (advanced performance) Control section CSH01.1C (standard performance) CSH01.3C (advanced performance) Option modules ENS (encoder interface) MA1 (analog I/O extension) Fieldbus optional (see chapter 7.7 "Input signal via fieldbus bus system") Software components The following software components are necessary Drive firmware FWA-INDRV*-MPH-05VRS-XX-1-NNN-MP (standard performance) FWA-INDRV*-MPC-07VRS-XX-1-NNN-MP (advanced performance) Application software with parameter set FWS-MLDTFA-SVP-02VRS-NN-IMM-XXXXX (standard performance) FWS-MLDTFA-SVP-12VRS-NN-IMM-XXXXX (advanced performance)

20 20/100 Bosch Rexroth AG Application description RE AW/06.10 Information on this product 4.4 Identification of software and parameter set The software and the related data set can be clearly identified by means of the file names. Identification by means of file designation Description column Example: F W S - M L D T F A - S V P V R S - N N - I M M H 2 1. Firmware connection 1. 1 FWS = Firmware option 2. Control section assignment 2. 1 MLDTFA = IndraMotion MLD / Technology function / ADVANCED control section 3. Application software 3. 1 SVP = Servo-variable pump 4. Software release VRS = Standard performance VRS = Advanced performance 5. Language package 5. 1 NN = Language independent 6. Applications 6. 1 IMM = Injection molding machine 7. Parameter set hardware assignment H2 = Parameter set for hardware set 150 H Fig. 3: Type key of software and parameter set If the technology function is integrated in a control section and active, it identifies itself. The version identifier can be read out using parameter P and is stored as decimal value. Identification by means of parameter entry Short text column Example: = P (decimal) 1. Series identification = S00 2. Version identification = V02 3. Revision identification = R33 Fig. 4: Software identification upon system integration

21 RE AW/06.10 Application description Bosch Rexroth AG 21/100 Transport and storage 5 Transport and storage 5.1 Transporting software The software is usually supplied together with the firmware on a multimedia card (MMC). Accordingly, the transport provisions for the MMC apply. As this is a software product, there are only the special transport notes listed below: In case of dispatch by , the data must always be protected against unauthorized access by a coding system certified by Bosch (e.g. SECUDE secure mail or with another adequate coding mechanism (e.g. WinZip In case of dispatch by means of a Multimedia Card (MMC), appropriate protection against the destruction (e.g. electrostatic discharge) of the data carrier has to be ensured. Further information on the use of an MMC is provided in chapter 1.2 of the instructions for "Firmware for drive controllers...".

22 22/100 Bosch Rexroth AG Application description RE AW/06.10 Operating instructions for "IndraWorks Ds" 6 Operating instructions for "IndraWorks Ds" S and P parameters are the basis for the accomplishment of settings on a driveintegrated control section. They are the interface between user and firmware and/or application functions. In order to edit these parameters, the commissioning software "IndraWorks Ds" is used. It communicates with the control section via the serial interface. NOTE Uncontrolled starting of the drive unit. The system or components might be damaged. Safe the drive parameters after each parameter modification before deenergizing the drive unit. If parameters are edited by a user, they become directly effective and are saved in the main memory of the control section. If the control section is de-energized at this point in time, all edited data are lost. This is the reason why the data must be actively saved and copied in the flash memory of the control section. For this purpose, "IndraWorks Ds" provides the function "Save parameters on drive flash". Below, the access mechanism is explained: Fig. 5: Save parameters on drive flash

23 RE AW/06.10 Application description Bosch Rexroth AG 23/100 Functional description 7 Functional description Field of application With the application software for SvP, servo-variable pump drives for hydraulic aggregates in injection molding machines can be realized. They can be operated in pressure/flow control mode (p/q control) or only in flow control mode (Q control). The application software is adjusted by parameterization. The implemented controller algorithm realizes a pressure and flow control. The pressure and flow command values can be provided electrically as analog command values or via a fieldbus bus system to the drive controller. The actual pressure value is recorded by a pressure transducer at the pump output and supplied to the drive controller. The drive controller controls the speed of the electrical motor so that the pump driven by it displaces exactly the oil quantity corresponding to the flow command value or that is required for providing the command pressure. Customer-specific hydraulic system U p Pressure command value provision Flow command value provision Application controller Closed-loop speed control M Fig. 6: System structure SvP for controlling pressure and speed 7.1 Modes of operation General The application software supports five different modes of operation: Standby operation (ro, Dr) Parameter mode (PM) Automatic mode (AU/DR) Error mode (Error) Reset mode (Reset) Parameterizable, further functions can be connected: Analog input monitoring (see chapter "FA4A0001 pressure transducer monitoring") Automatic offset correction for analog inputs (see chapter 7.8 "Automatic offset correction")

24 24/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Fig. 7: State model

25 RE AW/06.10 Application description Bosch Rexroth AG 25/100 Functional description Standby operation Standby operation is automatically reached after every re-start, if no error was generated or identified during ramp-up. In this mode of operation, the drive controller is fully functional and waits for the power connection for the converter. The display of the drive controller indicates "ro" for "ready for operation" and in addition, notified with signal level "H" via the relay contact X31.2. If the power of the converter is connected by the relay contact X31.9 according to the electrical wiring diagram (Fig. 26:and/or Fig. 27:, chapter 8.3 "SvP controller assembly"), this is immediately notified by the message "Dr" for "Drive ready". For information on the functions in standby operation, please see chapter 7.8 "Automatic offset correction" Parameter mode The parameter mode is activated by switching the "PM" pushbutton in the menu bar of the commissioning software "IndraWorks Ds". Fig. 8: "IndraWorks Ds" menu bar The status of the parameter mode is displayed at the standard operating unit of the control section with the message "PM". Now, the drive parameters can be changed. The parameter mode is usually only used when the drive controller is switched on for the first time in order to adjust the machine data. During parameter mode, the motor is torque-free. The parameter mode can be quit by pressing the "OM" pushbutton in the menu bar. In this case, the system directly switches to "standby mode". It is also possible to select the parameter mode by using the standard operating unit at the drive-integrated control section. Fig. 9: Standard operating unit This is how you can select the parameter mode: Keep "Esc" + "Enter" key simultaneously pressed. As soon as the selection is indicated on the display, you are in the menu structure and can navigate with the arrow keys. The selection request is in menu item As soon as the selection request shows ">PM", you must press the "Enter" key and select the parameter mode. You can quit the parameter mode by activating the select request ">ro".

26 26/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Via the standard operating part, parameters can only be entered to a limited extent. We therefore recommend using the comfort display or the commissioning software "IndraWorks Ds" for parameter editing. The user can change all system parameters according to the description in chapter 9 "Parameter". The parameter mode can only be selected, if the automatic mode is activated, and the drive has, however, not been started, yet. Should you try anyway, you can neither select the parameter mode, nor an error message is issued. If the user is connected to the control section by means of IndraWorks Ds during this inadmissible event, the following message is displayed. Fig. 10: Message upon switch-over from OM to PM with available release Automatic mode By default, the automatic mode is started with signal level "H" at the "Enable Drive" input (X31.3), after the "Automatic offset correction" function (see chapter 7.8 "Automatic offset correction") has been switched according to the settings. The started drive release is notified on the display by means of the message "AU". From this point in time, the torque of the drive is engaged and is subject to the pressure and speed provision according to the system behavior. If the "Enable Drive" release is canceled, the torque of the drive is disengaged and pressure and flow is not controlled anymore. If before, there was pressure in the system, it is discharged system-specifically to the tank via the the hydraulic displacer. NOTE Uncontrolled movement of the hydraulic displacer The system or components might be damaged. Set the command value provisions for pressure and flow to 0 before taking back the release. This actively reduces the system pressure to the minimum pressure.

27 RE AW/06.10 Application description Bosch Rexroth AG 27/100 Functional description Error mode Depending on the current mode of operation of the control section, numerous errors are monitored. If a faulty condition is recognized that impairs or prevents proper operation, the drive firmware or the application software generates an error message. The error message is shown on the display of the control section and additionally at the "Error message" output (X32.7) with signal level "H". If the error cause has been remedied, deletion of the error memory can be triggered via the "Error reset input (X32.8). Without pending errors but with pending signal level "H" at the "Enable Drive" input, drive is enabled immediately. For a more far-reaching error description refer to chapter 11 "Troubleshooting". 7.2 Command management Basic information Scope of functions Description The application software includes the command management function. Several functions are provided which can be initiated from the parameter field (P ). For standard applications of the SvP for p/q control, the command management is not necessary, or only necessary if further functionalities are to be used. For the application of advanced functionalities deviating from standard parameterization, please refer to your responsible contact partner at Bosch Rexroth. The command management offers the following functions: Selection of different user levels Login Logout Change password Permanent login Cancel permanent login Recalculate checksum Select PM Select OM Make a reset There are two parameters for navigating in the command structure Parameter P is used for the input of commands in the form of defined figures. The second parameter P is used to inform the user about the current status. Table 7: Command structure Parameter Description P P Input parameter for commands Display parameter for navigation and functional sequence Commands are entered via parameter P by entering a value and confirming it with "Return". The acceptance of commands can be recognized if the input cell is overwritten with the value "0".

28 28/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description The display of parameter P-O-1301 must be read according to the following illustration and interpreted accordingly: Description column Example: = P (decimal) 1. Path coding 00...= main menu 01...= user tools 11...= login 12...= logout 13...= change password for customer 14...= change password for application engineer 15...= change password for system engineer 16...= change password for development engineer 17...= permanent login 18...= remove permanent login 02...= parameter tools 21...= validate parameter 03...= application tools 31...= activate PM 32...= activate OM 33...= reset error 2. Placeholder 0 = Space 3. User coding 10 = Development engineer 20 = System engineer 30 = Application engineer 40 = Customer engineer 50 = not logged in Fig. 11: Display P User levels The main part of the command management is the administration of the user levels. Various additional functionalities deviating from standard parameterization can only be selected by users of a certain user level who are logged in. The following user levels are available: Not logged in The "Not logged in" user is not authorized to change P parameters. Customer The "Customer" user is authorized to edit the values indicated during commissioning, and to adjust the application software to the conditions of the existing machine, as well as to select PM, OM and Reset. In the condition as supplied, the user is logged in as "Customer". Application Engineer The "Application Engineer" user can select and parameterize additional functions. If the use of such functions is required, please refer to your responsible contact partner at Bosch Rexroth. The illustration of the command structure only shall provide an overview of functions. If you want to use it, please refer to your contact partner at Bosch Rexroth.

29 RE AW/06.10 Application description Bosch Rexroth AG 29/100 Functional description Fig. 12: Command menu structure - "main menu"

30 30/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Fig. 13: Command menu structure - "user tools"

31 RE AW/06.10 Application description Bosch Rexroth AG 31/100 Functional description Fig. 14: Command menu structure - "parameter tools" application tools P = 030xx P = 1 and user is authorised activate PM P = 310xx is the actual mode OM, it will be switched to PM switched or 99 P = 2 and user is authorised activate OM P = 320xx is the actual mode PM, it will be switched to OM switched or 99 P = 3 and user is authorised reset error P = 330xx exists an error, it will be reseted switched or 99 Fig. 15: Command menu structure - "application tools"

32 32/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description 7.3 Motor fan control The motor fan control is an optional function which switches the digital output X32.6 via parameter P bit 2 depending on the current motor temperature. The switching signal is provided permanently and can be wired as well, if necessary. The characteristic of the switching function corresponds to that of a two-position controller and/or Schmitt trigger. As motor temperature, the winding temperature of the drive (S ) is used. The switch-on threshold is specified in parameter P [12], and the switch-off threshold is set in parameter P [13]. Default values are assigned to both switching thresholds, which can be adjusted, if necessary. The switching function of the motor fan control is low-active. Low-active means: the fan is switched off if signal level "H" is present at the digital output; the fan is switched on, if signal level "L" is present. Table 8: Parameters for fan control Parameter Setting Unit Description S C Current motor winding temperature P [12] 80 C Switch-on threshold for fan P [13] 60 C Switch-off threshold for fan 7.4 Double pump selection The double pump selection function allows for the generation of a digital output signal with switching hysteresis depending on pressure threshold. One application sample is the switching of a hydraulic displacer unit in a double pump network against the tank. Table 9: Parameters for double pump selection Parameter Setting Unit Description P [67] 110 bar Switch-off threshold for double pump P [68] 90 bar Switch-on threshold for double pump Fig. 16: Double pump selection

33 RE AW/06.10 Application description Bosch Rexroth AG 33/100 Functional description The control signal is calculated depending on the current system pressure (from pressure transducer). If the switch-on threshold is exceeded, a hydraulic displacer is switched against the tank and the digital output is set to "H". If the switch-off threshold is undershot, it is reconnected to the system by setting the digital output to "L". The output signal of the double pump selection is assigned to parameter P and can be tapped at X32.9 via the digital output. 7.5 Master-slave operation General Master-slave switch-over The master-slave function is used for coupling several SvP systems to form a system network. No additional software or hardware is required. Each SvP system can both be used as master and slave. The use of the SvP application as master means that the application executes a p/q control according to the system behavior and the command value provisions. If the drive is operated as slave, it will operate in speed control according to the command value provision without consideration of the system pressure. A system network consisting of one master and one or more slaves is used whenever the required hydraulic performance is so high that it cannot be realized by a single SvP application. In the condition as supplied, operation is master by default. In order to switch over from master to slave operation, signal level "H" must be applied to the digital input X31.6 (P ). If the SvP application is operated as slave, only the command value provision is used at the corresponding analog input. The signals at the pressure command value input and at the actual pressure value feedback are not require and are ignored during operation. It is possible to switch dynamically between master and slave function. As setting parameter for the slave function, parameter P [35] must be used. With this parameter, the minimum speed for the slave can be specified. It can comply with the complete travel range of the master (e.g. ±3500 rpm), or it can be only positive speed if for example the slave drive is located downstream of the check valve. Table 10: Setting of the slave Parameter Setting Unit Description P [35] 0 rpm Minimum speed for the slave

34 34/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Below you can see application examples for a master/slave (M/S) operation: Actuator Actual pressure value U p Pressure command value provision Speed command value provision Master SVP M M Slave SVP Actual speed value master / Speed command value slave Fig. 17: M/S without check valve If a check valve is used, both slave and master must actively reduce pressure. For this purpose, P [35] must be set to the maximum permissible negative speed. Actuator Actual pressure value U p Pressure command value provision Speed command value provision Master SVP M M Slave SVP Actual speed value master / Speed command value slave Fig. 18: M/S with check valve If a check valve is used and pressure is reduced solely by the master, parameter P [35] must be set to the value "0" in order to avoid the cavitation of the hydraulic replacer at the slave side.

35 RE AW/06.10 Application description Bosch Rexroth AG 35/100 Functional description Actuator 1 Actuator 2 Actual pressure value 1 U p p U Actual pressure value 2 Pressure command value provision 1 Speed command value provision 1 Master SVP M M Master / Slave SVP Actual speed value master / Speed command value slave Slave mode selection Pressure command value provision 2 Speed command value provision 2 Fig. 19: Dynamic use of the M/S function If the SvP application is operated as master and as slave, a command value of pressure and speed must be provided during the complete master mode. The input signal at X31.6 must have the signal level "L". In this state, an independent hydraulic system can be supplied. If switched to slave mode, speed must be provided by the master, and signal level "H" must be applied to X31.6. In this example, due to the check valve, the minimum speed of P [35] in slave mode must be "0" in order to avoid the cavitation of the replacer. NOTE Cavitation of the hydraulic replacer The hydraulic replacer might be damaged by cavitation. Check parameter P [35] for correct setting according to the hydraulic connection of the slave axis. 7.6 Leakage compensation General The function of leakage compensation offers the alternative of controlling the flow command value. The value is calculated from the speed command value and the system leakage. By activating leakage compensation, the leakage of the hydraulic replacer is compensated. Leakage determination Before carrying out leakage compensation, the leakage of the system must be measured by automatic test processes. This step is usually carried out by the user during commissioning. For the determination of the leakage, a system in "AU/DR" condition is required. All actuators such as the valves of the system must be closed.

36 36/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Leakage determination is started in the commissioning software "IndraWorks Ds" by assigning signal level "H" to parameter P-O The function is started by a positive clock edge. After activation, the system pressure is automatically increased to a test pressure of 100 bar. As soon as the pressure is reduced to minimum value again, leakage determination is completed and the SvP application follows the command value provided by the command communication. The determined leakage correction value is stored in parameter P [112]. Leakage compensation The function and application of the leakage correction value and thus the switchover from speed command value provision to flow command value provision is activated by the digital input X31.7 (P ). If signal level "H" is applied, the system is controlled by the flow command value provision, otherwise by the speed command value provision. Table 11: Parameters for leakage correction Parameter Setting Unit Description P [112] 0 rpm/bar Leakage correction value P Bit 22: Activation of leakage determination Bit 23: Activation of leakage compensation 7.7 Input signal via fieldbus bus system General The default parameter set specifies that all command value provisions are provided via the analog and digital interfaces of the drive-integrated control section. If the machine is provided with a fieldbus bus system, it can be used as interface for command value provisions and control signals. For this purpose, the application function is provided with the option to apply all command and actual values selectively to the fieldbus bus system. This requires the use of a corresponding option module for the drive-integrated control section. The following fieldbus option modules for the control section CSH01.1C with firmware MPH05VRS are available: SE (Sercos 2) PB (profi bus) PL (parallel interface) CO (CANopen/ DeviceNet) S3 (Sercos III) The following fieldbus option modules for the control section CSH01.3C with firmware MPH07VRS are available: SE (Sercos 2) PB (profi bus) PL (parallel interface) CO (CANopen/ DeviceNet) S3 (Sercos III) ET (Multi-Ethernet) CCD (cross communication) - always available

37 RE AW/06.10 Application description Bosch Rexroth AG 37/100 Functional description Source signal selection In the application software, it is possible to selectively configure which of the analog or digital signals shall be read in via the fieldbus bus system. For this purpose, two control words are provided, one of which includes the selection of the digital input signals (P [0], and the other control word includes the selection of the analog input signals (P [5]) (see Table 12:). On signal level "L", "analog/digital" is selected for each signal as a source, on signal level "H", "fieldbus" is selected accordingly. Table 12: Source signal selection Parameter Setting Description P [0] 0 Selection of digital inputs Bit 6: Start of offset compensation Bit 8: Parameter selection 0 Bit 9: Parameter selection 1 Bit 12: Release signal Bit 13: M/S selection Bit 14: Reset Bit 23: Activation of leakage compensation P [5] 0 Selection of analog inputs Bit 0: Speed command value for p/q control Bit 1: Pressure command value for p/q control Bit 3: Speed command value for slave mode With each source signal selection, the source parameter is selected. The mapping for the analog input assignment is already included in the default parameter set. If a fieldbus bus system is used, the source parameters must be mapped with the commissioning software "IndraWorks Ds" according to the use of an option card extension. Table 13: shows the assignment of the source signals to the parameters: Table 13: Signal assignment Parameter Start of offset compensation Parameter for source selection "analog/digital" P Parameter for source selection "Fieldbus" P Parameter selection 0 P P Parameter selection 1 P P Release signal P P Slave selection P P Reset P P Activation of leakage compensation Speed command value for p/q control Pressure command value for p/q control Speed command value for slave mode P P P P P P P P

38 38/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description If using a fieldbus bus system, please note that you only use the parameters indicated in this manual for the control of the SvP system. In case of drive control using fieldbus control words, malfunctions of the commissioning software might occur, or the application software cannot be executed anymore. For questions with regard to project planning, please refer to your contact partner at Bosch Rexroth. 7.8 Automatic offset correction General Upon request, the function of automatic offset correction will perform a zero compensation for the analog inputs. The analog inputs to be compensated can be selected by a control word (P [3]). A signal is released for offset correction via signal level "H". An automatic offset correction is usually performed during the commissioning of an application. Compensation is performed by setting and resetting parameter P In the default parameter set, this bit is not mapped on inputs and must be specified by the commissioning software "IndraWorks Ds". When using this function, please make sure that the system is depressurized and no command values are provided. During offset correction, the deviations of the applied voltage values at the inputs are measured and stored in the assigned parameters (e.g. P [440] for the actual pressure value). Table 14: Parameters for offset correction Parameter Setting Unit Description P [3] 0 - Selection of offset correction Bit 0: Flow command value provision Bit 1: Pressure command value provision Bit 2: Actual pressure value Bit 3: Speed command value provision P [400] 0 mv Correction value for flow command value provision P [420] 0 mv Correction value for pressure command value provision P [440] 0 mv Correction value for actual pressure value P [460] 0 mv Correction value for speed command value provision (slave operation) P Bit 6: Start of offset correction The function of the offset correction does not replace the setting of the standardization for commissioning! Therefore, analog inputs should always be standardized according to the commissioning instructions. NOTE Uncontrolled start of the hydraulic displacer When copying a parameter set to machines with different hardware configuration and correction values other than "0", the system or components might be damaged. When copying to another machine, you must set the correction values for analog inputs to the value "0", or you must carry out the offset correction once again at the new machine before release.

39 RE AW/06.10 Application description Bosch Rexroth AG 39/100 Functional description 7.9 Parameter adjustment Adjustment to system rigidity General Target description Functional description Assignment of the data set selection for digital input encoding By means of data set selection, it is possible to select between different data sets. This allows for the simple optimization with regard to the system rigidity. The parameter selection offers the option to store individual settings at control parameters and to select them via digital inputs. The four parameter sets are assigned by default with an assignment which is independent of the system volume. Thus, it is possible to quickly select between different parameter sets for a defined machine size and/or axis on a machine without much application efforts. If individual parameterizations are required, the parameter sets can be applied individual by means of the commissioning software "IndraWorks Ds" and a PC. A possible application is the storage of optimized parameters for different machine sizes and/or axes. This means that data sets for up to four machine sizes or axes are stored in one parameter set. The adjustment to machine size and/or axis must be accomplished by selecting the digital inputs in accordance with each data set. In a default parameter set, the parameters of different machine sizes and/or axes are assigned as follows, whereas the system volumes must be regarded as guidelines: Data set 0: System volume < 1 l Data set 1: 1 l <= system volume < 3 l Data set 2: 3 l <= Systemvolumen < 6 l Data set 3: 6 l < system volume The parameter adjustment function is responsible for the management of the pressure control parameters. For this purpose, there are four different pressure control data sets between which you can change to runtime. Each data set reflects the optimized parameters for each hydraulic system volume. Via the two digital inputs at the parameters P and P , you can switch between the four data sets: "Setting parameter set PS0" at X31.4 "Setting parameter set PS1" at X31.5 Table 15: Data set selection PS1 PS0 Selected data set [index] L L 0 L H 1 H L 2 H H 3

40 40/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Pressure-dependent parameter selection within one data set Adjustment to system pressure Each data set consists of parameters for gain (KP), for reset time (TN), for derivative time (TV), as well as two adaptation factors. An optimization overview is provided in chapter 7.10 "Application controller". Table 16: Control parameters for pressure control Parameter Setting Unit Description Data set P [204] 1000 rpm/(1000*bar*ms) Reset time TN [0] 0 P [205] 1000 rpm/(1000*bar*ms) Reset time TN [1] P [206] 1000 rpm/(1000*bar*ms) Reset time TN [2] P [207] 1000 rpm/(1000*bar*ms) Nachstellzeit TN [3] P [208] rpm*ms/(1000*bar) Derivative time TV [0] P [209] 0 rpm*ms/(1000*bar) Derivative time TV [1] P [210] 0 rpm*ms/(1000*bar) Derivative time TV [2] P [211] 0 rpm*ms/(1000*bar) Derivative time TV [3] P [214] rpm/1000 bar Gain KP P [217] µs Adaptation factor 1 P [218] µs Adaptation factor 2 P [229] 1100 rpm/(1000*bar*ms) Reset time TN [0] 1 P [230] 1000 rpm/(1000*bar*ms) Reset time TN [1] P [231] 1000 rpm/(1000*bar*ms) Reset time TN [2] P [232] 1100 rpm/(1000*bar*ms) Reset time TN [3] P [233] rpm*ms/(1000*bar) Derivative time TV [0] P [234] 0 rpm*ms/(1000*bar) Derivative time TV [1] P [235] 0 rpm*ms/(1000*bar) Derivative time TV [2] P [236] 0 rpm*ms/(1000*bar) Derivative time TV [3] P [239] rpm/1000*bar Gain KP P [242] µs Adaptation factor 1 P [243] µs Adaptation factor 2 P [254] 800 rpm/(1000*bar*ms) Reset time TN [0] 2 P [255] 800 rpm/(1000*bar*ms) Reset time TN [1] P [256] 800 rpm/(1000*bar*ms) Reset time TN [2] P [257] 800 rpm/(1000*bar*ms) Reset time TN [3] P [258] rpm*ms/(1000*bar) Derivative time TV [0] P [259] 0 rpm*ms/(1000*bar) Derivative time TV [1] P [260] 0 rpm*ms/(1000*bar) Derivative time TV [2] P [261] 0 rpm*ms/(1000*bar) Derivative time TV [3] P [264] rpm/1000*bar Gain KP P [267] µs Adaptation factor 1

41 RE AW/06.10 Application description Bosch Rexroth AG 41/100 Functional description Parameter Setting Unit Description Data set P [268] µs Adaptation factor 2 P [279] 1000 rpm/(1000*bar*ms) Reset time TN [0] 3 P [280] 1000 rpm/(1000*bar*ms) Reset time TN [1] P [281] 1000 rpm/(1000*bar*ms) Reset time TN [2] P [282] 1000 rpm/(1000*bar*ms) Reset time TN [3] P [283] rpm*ms/(1000*bar) Derivative time TV [0] P [284] 0 rpm*ms/(1000*bar) Derivative time TV [1] P [285] 0 rpm*ms/(1000*bar) Derivative time TV [2] P [286] 0 rpm*ms/(1000*bar) Derivative time TV [3] P [289] rpm/1000*bar Gain KP P [292] µs Adaptation factor 1 P [293] µs Adaptation factor Application controller General The application controller has the basic function of a PID controller plus application-specific functions. These functions allow for the optimal adjustment to a specific target system. An exemplary optimization of the application controller is only carried out for data set "0". Data sets can be optimized accordingly, if required Gain optimization In order to optimize the gain factor KP, you must start with the default parameters and set the value for all acting TN values to "0". Then you must reduce the KP value by approx. 50% and continuously increase it in steps of 2000 until the desired system behavior is achieved. The target is to maintain the lowest possible remaining control deviation without overshooting or instabilities. If overshooting or instabilities are recognized, the entered value must be reduced (see Fig. 20:).

42 42/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description p p command KP p actual Fig. 20: Gain optimization t Table 17: Parameterization of the dynamic gain factor KP Parameter Setting Unit Description Data set P [214] rpm/1000*bar Gain KP 0 P [239] rpm/1000*bar Gain KP 1 P [264] rpm/1000*bar Gain KP 2 P [289] rpm/1000*bar Gain KP Reset time optimization After gain optimization, reset time TN can be adjusted, if required. For the optimization of the reset time, you have to start with default parameters. If the rise time to a pressure command value with a pressure command value step is too slow, the TN[0] value has to be increased in order to achieve a steeper pressure increase. If the pressure overshooting is over 20 bar, it can be reduced by increasing TN[3]. In order to reduce instabilities during the leveling off process and to achieve a fast rise time, nevertheless, both values TN[1] and TN[2] must be optimized according to Fig. 21:.

43 RE AW/06.10 Application description Bosch Rexroth AG 43/100 Functional description TN [3] p TN [2] p command TN [1] TN [0] p actual t Fig. 21: Reset time optimization Table 18: Parameterization of the reset time TV Parameter Setting Unit Description Data set P [204] 1000 rpm/(1000*bar*ms) TN [0] 0 P [205] 1000 rpm/(1000*bar*ms) TN [1] P [206] 1000 rpm/(1000*bar*ms) TN [2] P [207] 1000 rpm/(1000*bar*ms) TN [3] P [229] 1100 rpm/(1000*bar*ms) TN [0] 1 P [230] 1000 rpm/(1000*bar*ms) TN [1] P [231] 1000 rpm/(1000*bar*ms) TN [2] P [232] 1100 rpm/(1000*bar*ms) TN [3] P [254] 800 rpm/(1000*bar*ms) TN [0] 2 P [255] 800 rpm/(1000*bar*ms) TN [1] P [256] 800 rpm/(1000*bar*ms) TN [2] P [257] 800 rpm/(1000*bar*ms) TN [3] P [279] 1000 rpm/(1000*bar*ms) TN [0] 3 P [280] 1000 rpm/(1000*bar*ms) TN [1] P [281] 1000 rpm/(1000*bar*ms) TN [2] P [282] 1000 rpm/(1000*bar*ms) TN [3]

44 44/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Derivative time optimization The derivative time TV is already optimized in the default parameter set and does usually not need to be adjusted. The rise behavior of the system can be optimized with the derivative time TV[0]: Increasing TV[0] slows down the rise behavior Reducing TV[0] accelerates the rise behavior p p command TV[0] p actual Fig. 22: Derivative time optimization t Table 19: Parameterization of the derivative time TV Parameter Setting Unit Description Data set P [208] rpm*ms/(1000*bar) TV [0] 0 P [233] rpm*ms/(1000*bar) TV [0] 1 P [258] rpm*ms/(1000*bar) TV [0] 2 P [283] rpm*ms/(1000*bar) TV [0] Adaptation factor optimization If despite an optimal controller setting, the overshooting during upward steps cannot be adequately suppressed, it can be reduced or even completely avoided by increasing adaptation factor 1. If despite an optimized controller, undershooting occurs during downward steps, this undershooting can be suppressed with adaptation factor 2. Please note that the response time of the system is, however, delayed due to these measures. A compromise between the application of this function and controller optimization has to be made.

45 RE AW/06.10 Application description Bosch Rexroth AG 45/100 Functional description p p command Adaptation factor 1 Adaptation factor 2 p actuals t Fig. 23: Adaptation factor optimization Table 20: Parameterization of the adaptation factors Parameter Setting Unit Description Data set P [217] µs Adaptation factor 1 0 P [218] µs Adaptation factor 2 P [242] µs Adaptation factor 1 1 P [243] µs Adaptation factor 2 P [267] µs Adaptation factor 1 2 P [268] µs Adaptation factor 2 P [292] µs Adaptation factor 1 3 P [293] µs Adaptation factor Inputs / outputs Standardization of the analog inputs and outputs In order to ensure the correct function of the application software, the input and output signals must be adjusted to the physical voltage ranges of the hardware connected to the inputs and outputs. For this purpose, the standardization function is available for every input and output. Standardization consists in each case of three values: Measuring range: output or display range of the measurement Voltage range: Value range of the voltage according to the measuring range

46 46/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description Voltage offset: Additive deviation of the voltage range from the measuring range Table 21: Standardization parameters Parameter Setting Unit Description Assignment P [402] rpm/1000 Voltage range P [404] mv Measuring range P [406] 0 mv Voltage offset P [422] mbar Voltage range P [424] mv Measuring range P [426] 0 mv Voltage offset P [442] mbar Voltage range P [444] mv Measuring range P [446] 0 mv Voltage offset P [542] mbar Voltage range P [544] mv Measuring range P [546] 0 mv Voltage offset Speed command value (input) Pressure command value (input) Actual pressure value (input) Actual pressure value (output) P [562] rpm/1000 Voltage range P [564] mv Measuring range Actual speed value (output) P [566] 0 mv Voltage offset Dead zone function The dead zone function delays the input data by a parameterizable value (dead time). The module can be connected for the "Speed command value" and "Pressure command value" analog inputs. The function is activated via the control word P [19]. The dead zone function delays a positive step of the command value provision as soon as it exceeds a specified threshold value. This threshold value can be individually determined for every analog input. These functions are useful if they are not assumed for command value generation by a superior control.

47 RE AW/06.10 Application description Bosch Rexroth AG 47/100 Functional description Command value Command value before dead zone function Command value after dead zone function Switching threshold Dead time t Fig. 24: Dead zone function Table 22: Parameterization of the dead zone function Parameter Setting Unit Description Assignment P [19] - - Channel selection for dead zone element and ramp function (activation with bit = 1): Bit 0: Speed command value for p/q control Bit 1: Pressure command value for p/q control P [408] 0 ms Delay time P [409] 0 rpm/1000 Switching threshold for dead zone element and ramp function P [428] 0 ms Delay time P [429] 0 mbar Switching threshold for dead zone element and ramp function - Speed command value Pressure command value Ramp functionality General The functionality of ramps allows for the limitation of the rise and fall time of an analog input signal. This function can be connected for the "Speed command value" and "Pressure command value" analog inputs. Activation is also performed by parameter P [19]. For rise and fall, two rise values are in each case offered, the function of which is described in the following. It must be noted that the dead zone and ramp function is activated using the same parameter P [19]. Ramps for rise Ramps for fall In a step of the input signal from a value below the switching threshold to a new value above the switching threshold, the output signal is brought to the new value using a ramp with the rise "rsloperise1". In a step of the input value completely above or below the switching threshold, the ramp rise is "rsloperise2". This is also the standard rise in case that "rsloperise1" takes the value "0". In a step of the input signal from a value above the switching threshold to a new value below the switching threshold, the output signal is brought to the new value

48 48/100 Bosch Rexroth AG Application description RE AW/06.10 Functional description using a ramp with the rise "rslopefall1". In a step of the input value completely above or below the switching threshold, the ramp rise is "rslopefall2". This is also the standard rise in case that "rslopefall1" takes the value "0". The time basis of the rise is 1 ms. Command value Command values after ramp function Command values before ramp function rsloperise 2 1s rslopefall 2 1s 1s rsloperise1 rslopefall 1 Switching threshold 1s t Fig. 25: Ramp function Table 23: Parameterization of the ramp function Parameter Setting Unit Description Assignment P [19] - - Channel selection for dead zone element and ramp function (activation with bit = 1): Bit 0: Speed command value for p/q control Bit 1: Pressure command value for p/q control - P [409] 0 rpm/1000 Switching threshold for dead zone element and ramp function P [410] 0 rpm/s Rise (rsloperise1) after exceeding the switching threshold in pos. direction P [411] 0 rpm/s Rise (rsloperise2) unless rsloperise1 Speed command value P [412] 0 rpm/s Fall (rslopefall1) after exceeding the switching threshold in neg. direction P [413] 0 rpm/s Fall (rslopefall2) unless rslopefall1 P [429] 0 mbar Switching threshold of dead zone element and ramp function P [430] 0 bar/s Rise (rsloperise1) after exceeding the switching threshold in pos. direction P [431] 0 bar/s Rise (rsloperise2) unless rsloperise1 Pressure command value P [432] 0 bar/s Fall (rslopefall1) after exceeding the switching threshold in neg. direction P [433] 0 bar/s Fall (rslopefall2) unless rslopefall1

49 RE AW/06.10 Application description Bosch Rexroth AG 49/100 Functional description Minimum command values It is possible for the analog inputs of the command value provision "Speed command value" and "Pressure command value" to define minimum values. The minimum admissible pressure is provided via parameter P [14] and the minimum speed is provided in parameter P [18]. The minimum permissible pressure limits the pressure command value provision downwards. The minimum speed limits the speed provision downwards if the actual pressure value falls below the minimum pressure. The default values are optimized for the application of the injection molding machine. If necessary, they can be adjusted to system-dependent features. Table 24: Parameterization of the minimum command values Parameter Setting Unit Description P [14] 5 bar Minimum admissible system pressure P [18] 200 rpm Minimum speed in case the minimum system pressure is not achieved

50 50/100 Bosch Rexroth AG Application description RE AW/06.10 Installation 8 Installation 8.1 Required tools Commissioning with PC For changing the application and for the initial commissioning by means of the PC, you need the following tools: Standard performance: PC with serial interface (D-SUB, 9-pole) Advanced performance: PC with Ethernet interface (RJ45) PC with "IndraWorks Ds" commissioning software Please make sure that the parameters of standard performance applications are changed via the serial interface of the control section, and the advanced performance applications are parameterized via the engineering Ethernet interface at the drive-integrated control section. For quick commissioning, a register card will be embedded in the project structure of "IndraWorks Ds" by means of which the application-specific parameters can be entered quickly and in a clearly laid out manner. In order to query the current status of this input assistance, please contact your responsible account manager at Bosch Rexroth. Commissioning without PC Alternatively, a commissioning without PC is possible. For this purpose, the comfort operating unit VCP01.2BWA-TS-NN-FW (material number: R ) must be used. By means of this operating unit, all parameters can be changed according to the commissioning instructions. In future, commissioning by means of a standard operating unit will be possible, which is a cheaper alternative. In order to query the current status of this input assistance, please contact your responsible account manager at Bosch Rexroth. 8.2 Required accessories MMC with application software For initial commissioning, an MMC with application software for SvP and the related firmware is required. Each SvP set has its own MMC with specific settings. If you have several machines of one size with an identical SvP set, you only need to order one MMC with the required information. If you have a set without MMC with related software, and if you need the application software, please refer to your contact partner at Bosch Rexroth. MMC without application software In order to transfer the commissioning software with stored parameters to another control section, the following accessories are required that are not included in the delivery contents and that you can order from Bosch Rexroth:

51 RE AW/06.10 Application description Bosch Rexroth AG 51/100 Installation Table 25: Necessary accessories for parameter transfer Component Material number PFM NW (MMC without firmware) R Interface cable In order to change the application parameters of the software and to accomplish the initial commissioning, the following accessories are required that are not included in the delivery contents and that you can order from Bosch Rexroth: Table 26: Necessary accessories for parameter editing at CSH01.C Component Material number IKB0041 (interface cable) R Table 27: Necessary accessories for parameter editing at CSH01.3C Component Material number Ethernet 10/100 Mbit/s RJ45 (Interface cable) SvP controller assembly For the assembly of a SvP system, the corresponding documentation of the hardware components has to be observed (see chapter 1.2 "Related documentation"). The pinout of the drive controller reflects a typical allocation according to the application-specific requirements of an SvP. In other applications, the I/O allocation may within the scope of the configuration possibilities of the technology function deviate from the illustration below.

52 52/100 Bosch Rexroth AG Application description RE AW/06.10 Installation Fig. 26: Input/output allocation at the drive controller (standard performance)

53 RE AW/06.10 Application description Bosch Rexroth AG 53/100 Installation Fig. 27: Input/output allocation at the drive controller (advanced performance)

54 54/100 Bosch Rexroth AG Application description RE AW/06.10 Installation Pressure transducer connection The pressure control loop is closed by means of the pressure transducer. It is recommended to use pressure transducer HM17. If a different pressure transducer is used, you must first check its compatibility. For pressure measurement, a pressure transducer with a voltage output within the range from 0 to 10 V must be used. We recommend a voltage offset for actual value output in order to be able to use the Cable break detection function (chapter "FA drive controller error"). The pressure transducer is connected to the plug terminals X32.4 and X32.5 of the control section. The signal line is to be connected to X32.4, the reference signal to X32.5. The measuring lines are to be shielded together and the shield has to be connected to X32.3. Fig. 28: Connection of the pressure transducer ENS encoder connection The encoder analysis ENS is connected at option port 1 of the control section. It analyzes signals from the encoder system of the series "IndraDyn S" motors (MSK motors). Connect the encoder of the motors with the encoder analysis ENS via an encoder cable Analog input and output connection The connection of the analog input and output signals except for the pressure signal of the pressure transducer (see chapter "Pressure transducer connection") is provided by a MA1 card. The MA1 card is an analog extension module and is integrated in the control section CSH01.1C at option port 3 or in the control section CSH01.3C at option port 2.

55 RE AW/06.10 Application description Bosch Rexroth AG 55/100 Installation The interface of the MA1 card is a 15-pole D-Sub socket. The MA1 card allows for the read-in of two voltage signals in the range from 0 V..10 V as well as for the output of two voltage signals in the range from -10 V V. Analog signals and reference signals are to be shielded and wired together. The shield must be applied to the housing of the converter. Fig. 29: shows the allocation of the analog input pins of the MA1 card. Fig. 29: Option module MA1 Assignment of the functions of the analog I/Os to the MA1 card Table 28: Option module MA1 allocation PIN designation Description Assignment 8 Housing Housing earthing - 15 GNDA Reference potential 7 GND100 Shield connection 14 +AA2 Signal line 6 GNDA Reference potential 13 GND100 Shield connection 5 +AA1 Reference potential Analog output 2 (current motor speed) Analog output 1 (current actual pressure value) 12 GNDA not connected 4 +AE2 Signal line 11 -AE2 Reference potential 3 GND100 Shield connection Analog input 2 (speed command value) 10 GNDA not connected 2 +AE1 Signal line 9 -AE1 Reference potential 1 GND100 Shield connection Analog input 1 (pressure command value)

56 56/100 Bosch Rexroth AG Application description RE AW/06.10 Parameter 9 Parameter This chapter contains the parameter description of the application software SvP. It serves for the specification and adjustment of the system components and the activation of functionalities. For system parameterization, the commissioning software "IndraWorks Ds" and the comfort operating unit are provided. Table 29: Parameter System parameters Index [x] Designation Unit Value range Default value Description S Bipolar speed limit rpm 0 to Value for the maximum permissible speed command value of the motor depending on the application and independent of the direction of rotation. S Speed controller proportional gain S Speed controller reset time Nm/ (rad/s) 0 to ms 0 to The speed controller calculates the torque/force command value ("P ") from the difference of the speed command value and the actual speed value (=S , speed control deviation). P Pressure command value provision, analog P Speed command value provision, analog V 0 to 10 0 Analog input for the pressure command value provision in master operation V 0 to 10 0 Analog input for the speed command value in master and slave operation P Digital l/o, - - P assignment list - - P P P P P S S P P P With parameter "P00300", the drive signals are allocated to the digital inputs/outputs of the control section by configuring the related IDN number in the list parameter P P Digital l/o, bit numbers In "P00301, digital I/O, bit numbers", the desired bit number which shall be assigned to the digital input/output is indicated for

57 RE AW/06.10 Application description Bosch Rexroth AG 57/100 Parameter Parameter Index [x] Designation Unit Value range Default value Description each assigned parameter (see P00300, digital I/O, assignment list). P Digital l/o, direction In "P00302, digital I/O, direction", the desired mode of operation (direction) is indicated for each assigned parameter (see P , digital I/O, assignment list). This means that it is defined whether it is a digital input or output. 11 S Motor temperature C - - This parameter shows the measured value of the temperature in the motor winding provided that the temperature sensor installed in the motor allows for analog temperature evaluation. P Analog output P Analog output, assignment A, signal selection (actual pressure value) P Analog output P Analog output, assignment B, signal selection (actual speed value) P Cooling type The series MSK motors may be operated on the basis of different cooling types. P External Ohm - Dependent Nominal braking resistor braking resistor on data hardware 1 W - Braking resistor continuous output

58 58/100 Bosch Rexroth AG Application description RE AW/06.10 Parameter Parameter Index [x] Designation Unit Value range Default value Description 2 kws - Max. refeed energy 3 V - Braking resistor switch-on threshold P Converter configuration - - Dependent on hardware Bit 8: Efficient braking resistor (internal/external) 0 = internal braking resistor activated at HCS02 (default) Device without (or with deactivated) braking transistor at HCS03/04. 1 = external braking resistor active (HCS02/ 03 /04) and internal braking resistor deactivated if an external braking resistor is connected (HCS02). P Gradient ramp rad/s 2 0 to P Delay ramp rad/s 2 0 to Maximum speed acceleration Maximum speed delay P Input parameter for commands P Display parameter for navigation and functional sequence P Software version P Incorrect parameter input Software version of the SvP application software. SxxVxxRxx One list element in P [x] is outside the permissible limits. The incorrect list element x is indicated here. P Error message Coded error display FAxxxxxx

59 RE AW/06.10 Application description Bosch Rexroth AG 59/100 Parameter Parameter Index [x] Designation Unit Value range Default value Description P Control word to 0 Source selection for digital signals between digital inputs P ( Bit = 0) or fieldbus P (Bit = 1) Bit 6: Start of offset compensation Bit 8: Parameter selection 0 Bit 9: Parameter selection 1 Bit 12: Release signal Bit 13: M/S selection Bit 14: Reset Bit 23: Activation of leakage compensation 2 Input value check after system start 3 Offset correction to to 0 Channel selection for the selection of the analog inputs to be checked (selection with bit = 1) Bit 2: Actual pressure value of pressure transducer 0 Channel selection for the selection of the input channels to be compensated (selection with bit = 1) Bit 0: Flow command value provision Bit 1: Pressure command value provision Bit 2: Actual pressure value Bit 3: Speed command value provision 5 Control word to 0 Source selection for analog signals between analog input (bit = 0) or fieldbus (bit = 1) Bit 0: Speed command value for p/q control Bit 1: Pressure command value for p/q control Bit 3: Speed command value in slave operation 12 Fan on C 0 to Switch-on threshold for fan control 13 Fan off C 0 to Switch-off threshold for fan control 14 Minimum pressure 16 Negative speed limit 18 Minimum speed bar 0 to Minimum admissible system pressure rpm 0 to Limitation of negative speed in master operation rpm 0 to Minimum speed in case the minimum system pressure is not achieved

60 60/100 Bosch Rexroth AG Application description RE AW/06.10 Parameter Parameter Index [x] Designation Unit Value range Default value Description 19 Ramp activation to 0 Channel selection for dead zone element and ramp function (activation with bit = 1): Bit 0: Speed command value for p/q control Bit 1: Pressure command value for p/q control 35 Minimum speed slave rpm to Minimum speed in slave operation 67 Double pump switch-on threshold bar 0 to 110 Switch-on threshold for double pump 68 Double pump switch-off threshold bar 0 to 90 Switch-off threshold for double pump 112 Leakage correction value rpm/bar to 0 Leakage correction factor, calculated by the application software 204 TN[0] rpm/(1000 *bar*ms) 0 to TN[1] rpm/(1000 *bar*ms) 206 TN[2] rpm/(1000 *bar*ms) 0 to 0 to Reset time constants, parameter selection TN[3] rpm/(1000 *bar*ms) 0 to TV[0] rpm*ms/(1 000*bar) 0 to TV[1] rpm*ms/(1 000*bar) 210 TV[2] rpm*ms/(1 000*bar) 0 to 0 to 0 0 Derivative time constants, parameter selection TV[3] rpm*ms/(1 000*bar) 0 to KP rpm/ (1000*bar) 0 to Gain factor, parameter selection Adaptation factor Adaptation factor 2 µs 1000 to µs 1000 to Adaptation factor for positive pressure overshooting, parameter selection Adaptation factor for negative pressure overshooting, parameter selection TN[0] rpm/(1000 *bar*ms) 0 to 1100 Reset time constant, parameter selection TN[1] rpm/(1000 *bar*ms) 0 to 1000

61 RE AW/06.10 Application description Bosch Rexroth AG 61/100 Parameter Parameter Index [x] Designation Unit Value range Default value Description 231 TN[2] rpm/(1000 *bar*ms) 0 to TN[3] rpm/(1000 *bar*ms) 0 to TV[0] rpm*ms/(1 000*bar) 0 to TV[1] rpm*ms/(1 000*bar) 235 TV[2] rpm*ms/(1 000*bar) 0 to 0 to 0 0 Derivative time constant, parameter selection TV[3] rpm*ms/(1 000*bar) 0 to KP rpm/ (1000*bar) 0 to Gain factor, parameter selection Adaptation factor Adaptation factor 2 µs 1000 to µs 1000 to Adaptation factor for positive pressure overshooting, parameter selection Adaptation factor for negative pressure overshooting, parameter selection TN[0] rpm/(1000 *bar*ms) 0 to TN[1] rpm/(1000 *bar*ms) 256 TN[2] rpm/(1000 *bar*ms) 0 to 0 to Reset time constant, parameter selection TN[3] rpm/(1000 *bar*ms) 0 to TV[0] rpm*ms/(1 000*bar) 0 to TV[1] rpm*ms/(1 000*bar) 260 TV[2] rpm*ms/(1 000*bar) 0 to 0 to 0 0 Derivative time constant, parameter selection TV[3] rpm*ms/(1 000*bar) 0 to KP rpm/ (1000*bar) 0 to Gain factor. Parameter selection Adaptation factor Adaptation factor 2 µs 1000 to µs 1000 to Adaptation factor for positive pressure overshooting, parameter selection Adaptation factor for negative pressure overshooting, parameter selection TN[0] rpm/(1000 *bar*ms) 0 to 1000 Reset time constant, parameter selection 3

62 62/100 Bosch Rexroth AG Application description RE AW/06.10 Parameter Parameter Index [x] Designation Unit Value range Default value Description 280 TN[1] rpm/(1000 *bar*ms) 0 to TN[2] rpm/(1000 *bar*ms) 0 to TN[3] rpm/(1000 *bar*ms) 0 to TV[0] rpm*ms/ (1000*bar) 0 to TV[1] rpm*ms/ (1000*bar) 285 TV[2] rpm*ms/ (1000*bar) 0 to 0 to 0 0 Derivative time constant, parameter selection TV[3] rpm*ms/(1 000*bar) 0 to KP rpm/ (1000*bar) 0 to Gain factor, parameter selection Adaptation factor Adaptation factor 2 µs 1000 to µs 1000 to Adaptation factor for positive pressure overshooting, parameter selection Adaptation factor for negative pressure overshooting, parameter selection Offset correction value mv to Measuring range rpm/ to 404 Voltage area mv to Voltage offset mv to Standardization for speed command value provision in p/q control 408 Delay time ms 0 to 0 Delay time for speed command value provision in p/q control 409 Switching threshold rpm/ to 0 Switching threshold for dead zone element and ramp function for speed command value provision in p/q control 410 rsloperise1 rpm/s 0 to 411 rsloperise2 rpm/s 0 to 0 Rise (rsloperise1) after exceeding the switching threshold in pos. direction for speed command value provision 0 Rise (rsloperise2) unless rsloperise1 for speed command value provision

63 RE AW/06.10 Application description Bosch Rexroth AG 63/100 Parameter Parameter Index [x] Designation Unit Value range Default value Description 412 rslopefall1 rpm/s 0 to 413 rslopefall2 rpm/s 0 to 0 Fall (rslopefall1) after exceeding the switching threshold in neg. direction for speed command value provision 0 Fall (rslopefall2) unless rslopefall1 for speed command value provision 414 Voltage range monitoring mv to Maximum permissible deviation from the permissible voltage range for speed command value provision in p/q control 420 Offset correction value mv to Measuring range bar/ to 424 Voltage area mv to Voltage offset mv to Standardization for pressure command value provision in p/q control 428 Delay time ms 0 to 0 Delay time for pressure command value provision in p/q control 429 Switching threshold mbar 0 to 0 Switching threshold for dead zone element and ramp function for pressure command value provision in p/q control 430 rsloperise1 bar/s 0 to 431 rsloperise2 bar/s 0 to 432 rslopefall1 bar/s 0 to 433 rslopefall2 bar/s 0 to 0 Rise (rsloperise1) after exceeding the switching threshold in pos. direction for pressure command value provision 0 Rise (rsloperise2) unless rsloperise1 for pressure command value provision 0 Fall (rslopefall1) after exceeding the switching threshold in neg. direction for pressure command value provision 0 Fall (rslopefall2) unless rslopefall1 for pressure command value provision 434 Voltage range monitoring mv to Maximum admissible deviation from the admissible voltage range for pressure command value provision

64 64/100 Bosch Rexroth AG Application description RE AW/06.10 Parameter Parameter Index [x] Designation Unit Value range Default value Description 440 Offset correction value mv to Measuring range bar/ to Voltage area mv to Voltage offset mv to Maximum admissible deviation from the admissible voltage range mv to Standardization for actual pressure value of pressure transducer 458 Voltage range for value control after restart. mv 0 to Offset correction value mv to Measuring range rpm/ to 464 Voltage area mv to Voltage offset mv to Standardization of speed command value provision in slave operation 474 Voltage range monitoring mv to Maximum admissible deviation from the admissible voltage range for speed command value provision in slave operation 542 Measuring range bar/ to Voltage area mv to Voltage offset mv to Standardization of actual pressure value output 562 Measuring range rpm/ to Voltage area mv to Voltage offset mv to Standardization of actual speed value output P Binary output field Bit 0: Warning message Bit 1: Error message

65 RE AW/06.10 Application description Bosch Rexroth AG 65/100 Parameter Parameter Index [x] Designation Unit Value range Default value Description P Binary inputs, digital P Binary inputs, fieldbus Binary inputs via digital inputs: Bit 6: Start of offset compensation Bit 8: Parameter selection 0 Bit 9: Parameter selection 1 Bit 12: Drive release Bit 13: M/S selection Bit 14: Reset Bit 22: Activation of leakage determination Bit 23: Activation of leakage compensation Binary input signals via fieldbus: Bit 6: Start of offset compensation Bit 8: Parameter selection 0 Bit 9: Parameter selection 1 Bit 12: Drive release Bit 13: M/S selection Bit 14: Reset Bit 22: Activation of leakage determination Bit 23: Activation of leakage compensation

66 66/100 Bosch Rexroth AG Application description RE AW/06.10 Commissioning 10 Commissioning General In the commissioning, the generally valid safety directives are to be observed. The commissioning may only be performed by specialists. In order to keep the time for the initial commissioning to a minimum, the instructions in the corresponding points are to be observed. For the following commissioning instructions, basic knowledge of the commissioning software "IndraWorks Ds" and the hardware components of the drive controller and the control section are required (see chapter 1.2 "Related documentation"). The procedure shown in the instructions is based on the commissioning software "IndraWorks Ds" (IndraWorks 09V ). When using other versions, deviations are possible. Procedure Initial condition In the commissioning, we recommend to proceed as follows: Upload of the software components to the drive-integrated control section according to chapter 10.1 "Software components upload" using the MMC: Load firmware according to the application software used Load application software and corresponding parameter set Check the hardware settings according to chapter 10.2 "Checking the hardware settings". If the hardware was delivered together with the application software, no changes are necessary and you can skip this point. Commission the application software according to chapter 10.3 "Commissioning of the application software": In the condition as supplied, the illustration of the inputs and outputs according to chapter "I/O configuration" is correctly assigned with standard parameterization. Therefore, usually no changes are required. We recommend, however, that you check the correct assignment for your application, nonetheless. In any case, you should check the configuration and standardization of inputs and outputs and adjust it to the system-specific application, if necessary. For a description refer to chapter to If the fan control function is used, the parameterization according to chapter "Fan control" must be made. The default parameters provide a functional configuration of pressure control (chapter "Pressure control") and closed-loop speed control ( "Closed-loop speed control"). If there are still instabilities in your system, you must optimize your system according to these two chapters. The initial condition for the adjustment of the SvP application software is an already existing communication of a PC via the commissioning software "IndraWorks Ds" with the drive-integrated control section. The control section must be connected and switched on according to the wiring specifications (see chapter 8.3 "SvP controller assembly"). The drive controller is in a condition as supplied. The application software with default parameter set as well as the related firmware are already installed on the control section. For the following settings, the drive controller must be in parameterization mode: The possibly necessary switch-over is shown in chapter 7.1 "Modes of operation".

67 RE AW/06.10 Application description Bosch Rexroth AG 67/100 Commissioning 10.1 Software components upload The software components are supplied with the MMC. The included data are assigned to the corresponding SvP set. NOTE Damage to the hydraulic displacer and to the system, or complete destruction. The incorrect parameterization of an SvP set with the data of another set may result in the uncontrolled operation of the drive which might damage or completely destroy individual components or the system. Only load MMC data to a SvP set according to the correct assignment Firmware loading You can load firmware to the drive-integrated control section with the MMC. The correct firmware for each SvP application is already available on the MMC in the condition as supplied. The following procedure must be observed when loading the firmware: Insert the MMC into the corresponding slot X7 at the controller, if not yet done so. Restart the drive with inserted MMC! After the drive is booted, the message "Firmware update?" appears on the standard operating unit (if this is not the case, please proceed with chapter ). Acknowledge this message by pressing the "Enter" key on the operating panel. Now, the inserted MMC loads the firmware to the drive. Proceed according to chapter Load SvP software and corresponding parameter set In the condition as supplied, the application software and the corresponding parameter set are on the MMC. The following procedure must be observed when loading the software and parameter set: After having executed the steps according to chapter , the message "Load param. from MMC" or "Load new param.?", depending on the operating state, is shown on the standard display. Acknowledge this message by pressing the "Enter" key on the operating panel. Now the application software for SvP and the related parameter set for the SvP set are loaded to the drive. After the controller is successfully booted, you must remove the MMC. The loading of software and parameters is finished.

68 68/100 Bosch Rexroth AG Application description RE AW/06.10 Commissioning 10.2 Checking the hardware settings Stop of the drive-integrated PLC Changes to the hardware must be communicated to the system according to the following steps. The drive controller must be activated for this purpose. Deactivate the technology function before checking the motor configuration. For this purpose, click the "Stop" field in the PLC control window. For activation, the corresponding "Run" field has to be actuated. The other settings of the figure are to be checked for correctness and adjusted accordingly, if necessary. Fig. 30: Run/Stop of the PLC control Motor configuration For the application of the SvP software, a motor with integrated encoder is used in the application. Check whether the drive logs in correctly on the drive-integrated control section via the encoder, and whether the correct cooling type is selected. Normally, you always use a ventilated motor. Check the motor data according to the following figure. Fig. 31: Checking the motor configuration

69 RE AW/06.10 Application description Bosch Rexroth AG 69/100 Commissioning Adjust the motor data accordingly, if the entered data do not comply with the motor. A detailed description is provided in the documentation "Firmware for drive controllers..." in chapter 1.2 "Related documentation" Field suppressor operation All motors with a Bosch Rexroth encoder have an internal encoder memory by means of which the drive logs in with its parameters on the drive-integrated control section. The configuration of the current and voltage control has a considerable influence on the maximum power of the drive. Fig. 32: Power increase Fig. 33: Field suppressor operation In case that during commissioning, the drive does not achieve the projected power according to the SvP set, you must check the setting of the field suppressor operation of the motor.

70 70/100 Bosch Rexroth AG Application description RE AW/06.10 Commissioning For motors with a 300-series winding (e.g. MSKXXXX-0300-XX..), the drive is not operated in field suppressor mode, i.e. the corresponding field is not set according to Fig. 33: "Field suppressor operation". For motors with a 200-series winding (e.g. MSKXXXX-0200-XX..), the drive is operated in field suppressor mode, i.e. the corresponding field is set according to Fig. 33: "Field suppressor operation". The field suppressor mode for motors with a 202-series winding is already activated. The corresponding parameters are stored in the encoder memory of the motor. If the field suppressor mode is not activated, please refer to your responsible contact partner at Bosch Rexroth Control cycle selection of position and velocity control The standard and advanced performance application software builds on control sections with different processors. Therefore it is necessary for all variants to adjust the control mode and thus the cycle time of the closed control loop for position and velocity to the corresponding control sections. The parameterization of the control mode is delivered by the default parameter set and must usually only be checked for correct setting. For standard performance, the "Standard" control mode must be selected, and for advanced performance, the "High performance" control mode must be selected. The following is a figure of the selection menu: Fig. 34: Control cycle selection Configuration of the braking resistor In the condition as supplied, the braking resistor is already configured, and no changes are required here. During initial commissioning, the settings must be checked for correctness and adjusted according to the following description, if necessary. Connected external braking resistors won't be automatically recognized by the control section and must therefore be configured manually. The change of the corresponding parameters can only be performed in parameter mode. If the internal braking resistor is used, the "External braking resistor" window must not be ticked. The data of the internal braking resistor is displayed automatically.

71 RE AW/06.10 Application description Bosch Rexroth AG 71/100 Commissioning If an external resistor is used, you must enable the "External braking resistor" checkbox in the window and enter the corresponding basic data unless they have been entered correctly. The following is a figure of the entry mask: Fig. 35: Braking resistor configuration Further parameter changes are not necessary as these are default parameterizations of the firmware Movement limit values The movement limit values are to be set according to the application. In this connection it is enough to set the bipolar limit, i.e. only one limit for positive and negative direction of rotation is necessary. If the entered limit value is "0", this limit is deactivated. NOTE Damage to the hydraulic displacer or complete destruction. If the hydraulic displacer unit is operated outside the admissible velocity limit, the displacer might be damaged or completely destroyed. Enter the maximum admissible speed for the hydraulic displacer unit for your application as bipolar limit.

72 72/100 Bosch Rexroth AG Application description RE AW/06.10 Commissioning Fig. 36: Setting the movement limit values The other entry parameters are to be maintained according to the standard allocation as also shown in the figure Torque limit values The torque limits must be checked and the maximum occurring torque values of a drive must be entered. If the maximum torque/force limit entered manually is too high, it will be limited by its own motor identification to the maximum admissible value, provided that an encoder is used. Please note that in case you enter the maximum torque limit below the actual limit according to the motor identification, the effected limit is not automatically increased. Refer to the following presentation. Fig. 37: Checking torque limit values

73 RE AW/06.10 Application description Bosch Rexroth AG 73/100 Commissioning Checking the correctness of the hardware settings The mode of operation is switched from parameterization mode to online mode using the pushbuttons in the commissioning software "IndraWorks Ds". Thus it is possible to check, whether configuration is consistent. Fig. 38: Switch-over between PM and OM If no errors occur, the system is switched into online mode. If, however, an error message is issued (as illustrated on the following figure), it is not possible to switch into online mode. The control remains in the parameterization mode. The errors according to the error message are to be remedied until no more errors occur and correct start-up into online mode is possible. For information on troubleshooting, please refer to chapter 11 "Troubleshooting". Fig. 39: Incorrect configuration 10.3 Commissioning of the application software Activation of the drive-integrated PLC PM/OM selection Change of application-specific parameters In the condition as supplied, the drive-integrated PLC is activated. If this is not the case or if errors occur, refer to chapter 10.2 "Checking the hardware settings" for the correct start of the PLC. As long as the unit has not been released for drive, you can switch between the operating modes "Parameter mode" and "Online mode" at any time by means of the user interface in "IndraWorks Ds" or on the display of the drive-integrated control section. Application-specific parameters are parameters which are responsible for the function of the application software. They are provided by the list parameter P and processed by the application software. Due to the program runtime of the standard performance variant, value changes of this list parameter might take a moment until the value change is effected. This process is accelerated if there is no drive release.

74 74/100 Bosch Rexroth AG Application description RE AW/06.10 Commissioning I/O configuration For changing the I/O configuration, "PM" must be selected as mode of operation. The mapping of I/O at relay X31/X32 is normally according to the following figure, and does not need to be changed by the user if standard parameterization is correctly applied. The correct setting of the parameters has to be checked. NOTE Incorrect function of the software. System components may be damaged or destroyed completely. Perform the input allocation as shown below. Deviating from the mapping shown below, only perform changes in parameter P and P according to the description in chapter 9 "Parameter". In case of any more far-reaching changes, you must imperatively contact our support (chapter 12.2 "Service and support"). Fig. 40: I/O configuration