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Sytronix

SvP 7020 IMCVariable-Speed Pump Drives

Commissioning ManualRE 62311-IB/11.2019

Edition 03

SytronixSvP 7020 IMCVariable-Speed Pump Drives

Commissioning Manual

DOK-SYTROX-SVP7020-I*C-CO02-EN-P

RS-d8249eb7a40ce9f10a347ea5017f1761-3-en-US-3

This document describes the functions, features and commissioning of thevariable-speed pump drive SvP 7020 IMC

Record of revisions Edition 03, 2019-11See tab. 1-1 "Record of revisions" on page 1

Copyright © Bosch Rexroth AG 2018All rights reserved, also regarding any disposal, exploitation, reproduction,editing, distribution, as well as in the event of applications for industrial prop‐erty rights.

Liability The specified data is intended for product description purposes only and shallnot be deemed to be a guaranteed characteristic unless expressly stipulatedin the contract. All rights are reserved with respect to the content of this docu‐mentation and the availability of the product.

Editorial department Dept. DC-IH/EBD-DOK

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Sytronix SvP 7020 IMC Variable-Speed Pump Drives

Table of ContentsPage

1 Sytronix system overview.............................................................................................. 11.1 About this documentation....................................................................................................................... 11.2 Explanation of signal words and the Safety alert symbol....................................................................... 21.3 Introducing the product........................................................................................................................... 31.4 Range of applications............................................................................................................................. 41.5 Sytronix components.............................................................................................................................. 51.6 Accessories ........................................................................................................................................... 51.7 Software/parameter file packages.......................................................................................................... 6

2 Safety instructions.......................................................................................................... 92.1 About this chapter .................................................................................................................................. 92.2 Intended use........................................................................................................................................... 92.3 Improper use........................................................................................................................................... 92.4 Qualification of personnel..................................................................................................................... 102.5 General safety instructions................................................................................................................... 102.6 Product- and technology-dependent safety instructions....................................................................... 112.7 Obligations of the machine end-user.................................................................................................... 14

3 General notes on material damage and product damage............................................ 15

4 Symbols and their use................................................................................................. 17

5 Introduction and basic principles of IMC...................................................................... 215.1 Application type.................................................................................................................................... 215.2 System requirements/components....................................................................................................... 215.3 Electrical system characteristics........................................................................................................... 255.4 Functional features............................................................................................................................... 275.5 Relevant parameters............................................................................................................................ 28

6 Commissioning............................................................................................................ 296.1 Establishing the connection to the drive controller............................................................................... 296.1.1 General information........................................................................................................................... 296.1.2 Requirements.................................................................................................................................... 296.1.3 Establishing the connection............................................................................................................... 296.2 Loading IMC project.............................................................................................................................. 346.2.1 Software/parameter file (*.par).......................................................................................................... 346.3 Configuring IndraDrive.......................................................................................................................... 356.3.1 Master communication...................................................................................................................... 356.4 IMC commissioning.............................................................................................................................. 546.4.1 Overview............................................................................................................................................ 546.4.2 Initial commissioning for IMC............................................................................................................. 556.4.3 Communication interface and I/O configuration................................................................................ 58

Sytronix SvP 7020 IMC Variable-Speed Pump Drives I

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RE 62311-IB/11.2019_ Edition 03 Bosch Rexroth AG

4.4 IMC controller – Parameter setting.................................................................................................... 696.4.5 Extended settings.............................................................................................................................. 796.4.6 Diagnostics including logbook........................................................................................................... 956.5 Configuring the protective functions..................................................................................................... 966.5.1 Introduction and overview.................................................................................................................. 966.5.2 IndraWorks dialog and areas of protective functions......................................................................... 986.5.3 Basic protection settings/default values............................................................................................ 996.5.4 Pressure limitation and monitoring.................................................................................................. 1016.5.5 Power limitation............................................................................................................................... 1056.5.6 Speed limitations............................................................................................................................. 1076.5.7 Thermal monitoring.......................................................................................................................... 1086.5.8 Limitation of the flow command value............................................................................................. 1116.5.9 Acceleration limitations.................................................................................................................... 1126.5.10 Detection of pipe damage................................................................................................................ 1136.5.11 Pressure sensor monitoring............................................................................................................. 114

7 Parameters and diagnostic messages for p/Q control injection molding (IMC)......... 1197.1 Relevant parameters.......................................................................................................................... 1197.2 Parameter description......................................................................................................................... 1207.3 P-0-1271, Active pressure command value........................................................................................ 1207.4 P-0-1275, Pump displacement - effective........................................................................................... 1217.5 P-0-1276, IMC controller cycle time.................................................................................................... 1227.6 P-0-1278, Disturbance observer term, limited.................................................................................... 1227.7 P-0-1280, Upper limit of disturbance observer, effective.................................................................... 1227.8 P-0-1281, Swivel angle feedback value.............................................................................................. 1237.9 P-0-1282, Speed command value in slave operation (master communication)................................. 1237.10 P-0-1285, Effective flow command value........................................................................................... 1247.11 P-0-1289, Effective max. velocity limitation ....................................................................................... 1257.12 P-0-1290, Effective min. velocity limitation......................................................................................... 1257.13 P-0-1295, Lower safe velocity limit..................................................................................................... 1257.14 P-0-1296, Max. safe positive speed limitation.................................................................................... 1267.15 P-0-1297, Min. safe positive speed limitation..................................................................................... 1267.16 P-0-1298, Actual degree of heat......................................................................................................... 1277.17 P-0-1299, Safe acceleration limitation................................................................................................ 1277.18 P-0-1300, Error/warning code............................................................................................................. 1277.19 P-0-1301, Flow feedback value.......................................................................................................... 1287.20 P-0-1311[0 ... 70] parameter set memory (4 sets).............................................................................. 1287.21 P-0-1311[200]], I - integral action time 2............................................................................................. 1307.22 P-0-1311[201], Filter time constant 2 switching threshold.................................................................. 1327.23 P-0-1311[204], Minimum speed in slave operation............................................................................ 1347.24 P-0-1311[208], Leakage compensation, determination speed........................................................... 1347.25 P-0-1311[209], Leakage compensation, determination pressure....................................................... 1357.26 P-0-1311[210], Injection: Pressure ratio, beginning of ramp, inject. phase speed limit...................... 1367.27 P-0-1311[211], Injection: Pressure ratio, end of ramp, injection phase speed limit............................ 1377.28 P-0-1312[0 ... 99], Error/warning history............................................................................................. 1377.29 P-0-1318, Cam, switch-on threshold.................................................................................................. 138

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Bosch Rexroth AG RE 62311-IB/11.2019_ Edition 03

30 P-0-1319, Cam, switch-off threshold.................................................................................................. 1397.31 P-0-1320, P-gain – set 2..................................................................................................................... 1407.32 P-0-1321, I-integral action time, set 2................................................................................................. 1407.33 P-0-1322, ParaSet: Switch point, set 2............................................................................................... 1417.34 P-0-1323, ParaSet: Switch point, set 1............................................................................................... 1417.35 P-0-1324, Injection: Smoothing time constant.................................................................................... 1427.36 P-0-1326, Factor of speed switching threshold for cam .................................................................... 1427.37 P-0-1327, Injection: Final speed, injection function............................................................................ 1437.38 P-0-1329, Acceleration limitation of pump speed............................................................................... 1447.39 P-0-1330, Deceleration limitation of pump speed............................................................................... 1447.40 P-0-1331, IMC control: Lower limitation of disturbance observer....................................................... 1457.41 P-0-1370, Configuration...................................................................................................................... 1457.42 P-0-1373, IMC control: P-gain............................................................................................................ 1487.43 P-0-1374, I-integral action time........................................................................................................... 1487.44 P-0-1375, IMC control: D-component/disturbance observer factor.................................................... 1497.45 P-0-1376, Upper limitation of disturbance observer........................................................................... 1507.46 P-0-1377, Flow command value......................................................................................................... 1507.47 P-0-1378, Controller output limitation, negative.................................................................................. 1517.48 P-0-1383, Lower limitation of D component........................................................................................ 1527.49 P-0-1384, PT1 command value filter, filter time constant, ascent...................................................... 1527.50 P-0-1385, PT1 command value filter, filter time constant, descent.................................................... 1537.51 P-0-1387, Sytronix message text........................................................................................................ 1537.52 P-0-1389, [100 ... 200] Protective function parameters...................................................................... 1547.53 P-0-1390, Control word....................................................................................................................... 1567.54 P-0-1410, Status word........................................................................................................................ 1577.55 P-0-1411, Cam status word................................................................................................................ 1587.56 P-0-1415, SF warnings....................................................................................................................... 1597.57 P-0-1416, SF error messages............................................................................................................ 1607.58 S-0-0800, Pressure command value.................................................................................................. 1607.59 S-0-0813, System pressure................................................................................................................ 1617.60 S-0-0827, Pressure control deviation................................................................................................. 1617.61 S-0-0832, Pressure window................................................................................................................ 1627.62 Error and warning messages for injection molding control (IMC) ...................................................... 1637.63 Troubleshooting guide........................................................................................................................ 164

8 Annex......................................................................................................................... 1698.1 Documentations.................................................................................................................................. 1698.1.1 Drive systems, system components................................................................................................ 1698.1.2 Firmware.......................................................................................................................................... 1698.1.3 Motor-pump unit.............................................................................................................................. 1708.2 Abbreviations...................................................................................................................................... 1718.3 Data entry pump for IMC ................................................................................................................... 172

9 Service and support................................................................................................... 175

Sytronix SvP 7020 IMC Variable-Speed Pump Drives III

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Page

Index.......................................................................................................................... 177

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1 Sytronix system overview1.1 About this documentation

Editions of this documentation

Edition Releasedate

Note

01 2016-10 First edition

02 2018-07 Updates on new software/parameter file IMC02V12, new IndraWorks dialogs.Configuration of IndraDrive (master communication) added.

03 2019-11 Updates on new software/parameter file IMC02V14, IndraWorks dialogs.Pressure sensor monitoring and pressure sensor cable break monitoring separated.

Tab. 1-1: Record of revisionsThis document describes the functions and features of the variable-speedpump drive SvP 7020 - Injection Molding Control (IMC). This drive solutioncan be used in applications for plastics machines or other pressure and flowcontrol applications.The main difference between the product ranges 7020 and 5020 lies in thedrive units. Sytronix 7020 uses drive units of the IndraDrive product range.Sytronix 5020 uses Rexroth EFC frequency converters. Besides, there aredifferences in terms of type and extent of communication and bus interfaces,as well as in terms of additional functionality and user interfaces.The following software/parameter file package is described in this document:● Injection Molding Control (IMC): for applications for plastics machines

with alternating p/Q control

Your Feedback Your experience is important for our improvement processes of products anddocumentations.If you discover mistakes in this documentation or suggest changes, you cansend your feedback to the following e-mail address:[email protected] need the following information to handle your feedback:● The number indicated under "Internal File Reference".● The page number.

Sytronix SvP 7020 IMC Variable-Speed Pump Drives 1/183

Sytronix system overview


mailto:[email protected]

Trademark information

Sercos® is registered trademark of Sercos International e.V.

EtherCAT® is registered trademark and patented technology, licensed byBeckhoff Automation GmbH, Germany.

EtherNet/IP™ is a trademark under license of Open DeviceNet VendorAssociation, Inc.

PROFIBUS® is registered trademark of PROFIBUS Nutzerorganisation e.V.

PROFINET® (Process Field Network) is the open Industrial Ethernetstandard of Profibus & Profinet International (PI) for automation.ProfiNet® is registered trademark of PROFIBUS Nutzerorganisation e. V.

CANopen® is registered trademark of CAN in Automation e.V.

TwinCAT® is registered and licensed trademark of Beckhoff AutomationGmbH, Germany

HIPERFACE® is registered trademark of SICK-STEGMANN GmbH

EnDat® is registered trademark of Dr. Johannes Heidenhain GmbH

MTS SENSORS® is registered trademark of MTS Sensor TechnologieGmbH & Co. KG

BALLUFF® is registered trademark of Balluff GmbH

1.2 Explanation of signal words and the Safety alert symbolThe Safety Instructions in the available application documentation containspecific signal words (DANGER, WARNING, CAUTION or NOTICE) and,where required, a safety alert symbol (in accordance with ANSIZ535.6-2011).The signal word is meant to draw the reader's attention to the safety instruc‐tion and identifies the hazard severity.The safety alert symbol (a triangle with an exclamation point), which pre‐cedes the signal words DANGER, WARNING and CAUTION, is used to alertthe reader to personal injury hazards.

DANGER

In case of non-compliance with this safety instruction, death or serious injurywill occur.

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http://www.sercos.de/

https://www.odva.org/

https://www.odva.org/

http://www.profibus.com/

WARNING

In case of non-compliance with this safety instruction, death or serious injurycould occur.

CAUTION

In case of non-compliance with this safety instruction, minor or moderate in‐jury could occur.

NOTICE

In case of non-compliance with this safety instruction, property damage couldoccur.

1.3 Introducing the productThe variable-speed pump drives of the Sytronix series cover a wide portfolioof pumps, controllers, motors and software that are suitable for many applica‐tions. Rexroth support machine manufacturers with project panning by usingsimulation models for system design and component selection. The best sys‐tem components can be selected thanks to scalable power and function.If a cascaded system is used, multiple Sytronix drives can be interconnectedto produce the flow rate required for the process in an efficient way. Sytronixsystems are available as preconfigured systems or individually configuredcomponents.Rexroth provide variable-speed pump drives of three performance classes:

Medium dynamics Sytronix FcP – frequency-controlled pump driveFcP systems are suited for standard applications with constant pressure con‐trol for open hydraulic systems up to 90 kW. Typical applications include ma‐chine tools, as well as secondary axis motions in different applications, suchas presses.Sytronix DRn – constant pressure system with hydromechanical pressurecontrolDRn systems combine a variable-speed drive and an axial piston pump ofvariable displacement. They are characterized by good dynamics and a highoverload capacity. The pump independently controls the required pressure,and the frequency converter sets the optimum speed in terms of energy effi‐ciency and noise. The system is particularly well suited for retrofitting existinginstallations and has been designed for the performance range of 4 kW andhigher.

High dynamics Sytronix SvP – servo-variable pump driveSvP systems use the high dynamics of synchronous motors with permanentmagnets and thus achieve significant energy savings. Their functions includeaxis control in open and closed hydraulic circuits that requires high dynamicperformance, as well as advanced electric and electrohydraulic control. Plas‐tics converting machines and presses are the main applications for this tech‐nology.

High performance and dynamics Sytronix DFEn – variable-speed drive using a pump with electronic pressureand flow rate control




DFEn systems are suited for high performance applications that demand thebest value for money. These systems use axial piston pumps of variable dis‐placement and are particularly suitable for retrofitting existing systems. Thedrives feature functions for axis control and provide high performance in openhydraulic circuits. This makes them suitable for use in machines with multiplehydraulic functions.

Fig. 1-1: Sytronix house

1.4 Range of applicationsAxis control (open-loop and

closed-loop)● In closed hydraulic circuits, the variable-speed drives of Sytronix SvP

provide dynamic and extensive electric and electrohydraulic control op‐tions. In open hydraulic circuits, the Sytronix DFEn system with electron‐ic pump control of pressure/flow rate (p/Q) represents an alternative.DFEn-based hydraulic drives extend the performance range and aresuited for machines with multiple hydraulic circuits.

● In cascaded systems, multiple Sytronix drives operate together to effi‐ciently produce the flow rate required for the process.

Constant pressure systems ● In constant pressure systems, the cost-saving Sytronix FcP/DRn driveswith VFD-operated asynchronous motors are compatible with conven‐tional drives up to 315 kW.

The figure below shows different applications for Sytronix solutions.

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Fig. 1-2: Sytronix solution

1.5 Sytronix componentsIntroduction The motor-pump units described in the product catalog (R999000332) can be

used in combination with the drive units of the IndraDrive range. Drives withconverters (IndraDrive C, IndraDrive Cs) or inverters (IndraDrive M) with theSvP 7020 solutions are suited for this purpose.The IndraDrive units consist of a power section and a control section for con‐trolling servo and standard motors. The part of the drive controller with thecontrol functions and interfaces for installation in the power section is calledcontrol section. The power component contains the power electronics forcontrolling the motors and includes the control section. The IndraDrive Crange, such as HCS, uses a three-phase current and generates different vol‐tages and frequencies from the three phase current. The IndraDrive M range,such as HMS, is connected to a DC current source with DC bus and gener‐ates different voltages and frequencies for controlling the motor speed andthe torque from the DC current source with DC bus..Main features of IndraDrive units:● Performance range from 100 W to 4 MW● High degree of overload capacity● Compact design for applications with a single axis● Can be connected to a converter for cost-saving solutions● Direct connection to three-phase current from 200 to 500 VAC

1.6 AccessoriesAn extensive portfolio of accessories is available for Sytronix systems.

Mains filter Mains filters ensure that the EMC limit values are complied with and sup‐press leakage currents generated by capacitors.

Braking resistors Braking resistors convert excessive energy in the DC bus into heat.Mains chokes Mains chokes reduce the harmonics in the power grid and increase the con‐

tinuous power of the DC bus.




Motor and encoder cables Motor and encoder cables connec the motor to the drive unit.Auxiliary components Accessories for connecting modules, such as HAS01, including contact bars,

fixing devices etc. The accessories include shielded motor cables for connec‐tion to drive units (HAS02), mounting flanges (HAS07) and cables for com‐missioning (RKB0001).

1.7 Software/parameter file packagesIntroduction The table below shows various options for combining the software/parameter

file packages with the Sytronix solutions IMC and PFC.

Hardware Software/parameter file

IMC02Vxx PFC02Vxx

CSH02.1CSB02.1HCS01.1

CSH02.1HCS01.1

Injection molding Hydraulic servo axis

System Drive Motor Pump p/Q control x/F control

SvP 7020 HCS, HMS MS2N, MSK PGM, PGH, A4, A10 X X

X Available- Not availableTab. 1-2: Overview of the software/parameter file for SvP 7020

Commissioning tool The “IndraWorks Ds/D/MLD“ commissioning tool (version 14V24 and higher)is used to commission the variable-speed pump systems SvP 7020.

Important features This section lists the functions contained in the software/parameter file (IMC).

Functions IMCPressure control x

Pressure command value filter (PT1 for ascent/descent) x

Unipolar speed limitation x

Acceleration/deceleration limitation x

Double pump operation/swivel angle switching (min.-max.) x

p→Q switching/minimum value generator x

Injection function x

Master-slave function, analog linking x

Power limitation, pump x

Automatic set switching - pressure-dependent (2 sets) x

Automatic set switching - power-dependent (2 sets) x

Parameter set switching - control (4 sets) x

Pressure sensor monitoring (cable break, observer) x

Pressure/speed range monitoring → function for pump protection x

Actual pressure value monitoring x

Pressure/speed command value limitation x

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Functions IMCFlexible hose failure detection x

Leakage compensation x

Flow command value limitation (min, soft start) x

x Available- not availableTab. 1-3: Overview of functions for IMC firmware package

Type codes and overview of the software/parameter files

Product Productname

Applicationtype

Version/Release

LanguageAttribute

Firmware /Target ver‐

sion

FWS_ MLDSYx_ IMC_ 02VRS_ D0_ MP20

FWS_ MLDSYx_ PFC_ 02VRS_ D0_ MP20

FWS Software/parameter file (compiled MLD project)MLDSYx IndraDrive MLD with SYTRONIX technology functionIMC Injection Molding Control function with p/Q controlPFC Position Force ControlD0 German and EnglishMP20 FWA-INDRV*-MPx-20VRS-D5-x-SYX-xxTab. 1-4: Overview of types

Hardware and firmware require‐ments

To use the Sytronix Software 02VRS, the IndraDrive solution requires the fol‐lowing firmware and hardware for the drive:

Product name Type Type code Brief description Firmware

Injection MoldingControl (IMC)

Sytronix_7020 FWS_MLDSYx_IMC_xxVxx_EN_MP20 System function with pres‐sure →flow rate control(p→Q)

MPx-20VRS

Position ForceControl (PFC)

Sytronix_7020 FWS_MLDSYx_PFC_xxVxx_D0_MP20 System function for axiswith position→force control(F→x)

MPx-20VRS

Tab. 1-5: Assigning the Sytronix technology functions to the IndraDrive firm‐ware

See also chapter 5 "Introduction and basic principles of IMC" on page 21




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2 Safety instructions2.1 About this chapter

This product was manufactured according to the generally accepted rules oftechnology. There is, however, still a risk of personal injury or materialdamage.Please observe the general safety instructions in this chapter and the safety-related guidelines and handling instructions in this manual. This will preventpersonal hazards, material damage and errors.● Read this documentation completely and thoroughly before working with

the product.● Keep this documentation 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 useThis product is an electro-hydrostatic drive system.The Sytronix system is exclusively intended for being integrated in a machineor for being assembled with other components to form a machine or anaggregate. It is only allowed to commission the Sytronix system, if it has beenintegrated in the machine for which it is intended.The Sytronix system may be operated as follows:● For pressure-controlled hydraulic supply (for SvP: with alternating flow

rate change, position control with alternating pressure or force control.● The Sytronix system is not suited to execute safety-relevant functions.

Safety-relevant functions can be implemented with the drive-integratedsafety technology or with a higher-level Safety control.

In the Sytronix system, the validation of the command values andactual values (pressure, force, position, speed and velocity) is notprovided.● Make sure that the validation is executed in the machine

control.

The application-specific adjustment of the parameters during initialcommissioning is allowed.The product is only intended for industrial use and not for private use.Operation according to the intended use also implies that you have read andunderstood this documentation completely, especially chapter 2 “Safetyinstructions“.

2.3 Improper useAny use other than described as intended use is improper use and thereforenot allowed.For damage in the case of improper use, Bosch Rexroth AG does notassume any liability. The user assumes all risks involved with improper use.


Safety instructions


2.4 Qualification of personnelThe operations described in this documentation require basic knowledge ofmechanics, hydraulics and electrics, as well as knowledge of thecorresponding terms. For transporting and handling the product, additionalknowledge of how to handle lifting gear and the necessary attachmentdevices is required. To ensure safe use, these activities may only be carriedout by an expert in the respective field or an instructed person under thedirection and supervision of an expert.Experts are those who are able to recognize potential hazards and apply theappropriate safety measures due to their professional training, knowledgeand experience, as well as their understanding of the relevant conditionspertaining to the work to be undertaken. An expert must observe the relevantspecific professional rules.These additional qualifications are required:● Knowledge of how to wire electrical components● Knowledge of how to parameterize the application software● Knowledge of hydraulics● Basic knowledge of control technology

2.5 General safety instructions● Observe the valid regulations on accident prevention and environmental

protection.● Heed the safety regulations and instructions of the country in which the

product is used.● Use Rexroth products only in proper technical state.● Please observe all notes on the product.● Persons who install, operate, dismount or maintain Rexroth products

must not consume any alcohol, other drugs or pharmaceuticals that mayaffect their ability to respond.

● Only use accessories and spare parts approved by the manufacturer toeliminate the risk of injury due to unsuitable spare parts.

● Comply with the technical data and ambient conditions specified in theproduct documentation.

● If unsuitable products are installed or used in safety-relevantapplications, unintended operational states can occur in theseapplications, which can cause personal injury and/or property damage.Therefore, only use the product in safety-relevant applications, if thisuse is expressly specified and permitted in the documentation of theproduct.

● You may only commission the product when it has been established thatthe final product (for example, a machine or system), in which theRexroth products have been installed, complies with nationalregulations, safety regulations and standards relevant to the application.

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Safety instructions



2.6 Product- and technology-dependent safety instructions

Danger of life, risk of injury, serious injuryduring work on a system which is underpressure.

WARNING

● Switch off all power-transmission-components and connections (electric,pneumatic, hydraulic) according to the manufacturer´s details andsecure them against restarting.

● Ensure that the motor-pump-unit is completely depressurized.● Do not disconnect any cable connections, plumbing connections and

components as long as the motor-pump-unit is retaining pressure.

Danger to life, risk of injury due to electricshock. High electric voltage over 50 volt.

WARNING

● De-energize the part of the installation before you mount the motor-pump-unit or connector or terminal box connections.

● Secure the plant against restarting.● Do measures and tests only with firmly connected protective conductor

of components on the provided points.● Please always wait 30 minutes after switch-off, so live capacitors

discharge before they have access to electric components. To excludeandy danger due to any contact, measure electric voltage of live partsbefore working.

● Do not touch any electric junctions of live components.

Danger to life, risk of injury by electric shock.High housing voltage and high leakagecurrent.

WARNING

● Before switching on and before commissioning, ground or connect themotor-pump-unit components to the equipment grounding conductors atthe grounding points.

● Connect the equipment grounding conductors of the motor-pump-unitcomponents permanently to the main power supply at all times. Theleakage current is greater than 3.5 mA.

● Use at least 10mm² copper cross-section for the total path of theequipment grounding conductor.

Danger of fire, explosion and pollution due toexisting oil dust due to defective orimproperly assembled sealings!

WARNING

● Do not do any welding on or near pressurized motor-pump-units.● Keep away open fire or ignition source from motor-pump-units.


Safety instructions


Protection against electromagnetic andmagnetic fields during operation andmounting

WARNING

Electromagnetic and magnetic fields!Health hazard for persons with active implantable medical devices (AIMD)such as pacemakers or passive metallic implants.● Hazards for the above-mentioned groups of persons by electromagnetic

and magnetic fields in the immediate vicinity of drive controllers and theassociated current-carrying conductors.

● Entering these areas can pose an increased risk to the above-mentioned groups of persons. They should seek advice from theirphysician.

● If overcome by possible effects on above-mentioned persons duringoperation of drive controllers and accessories, remove the exposedpersons from the vicinity of conductors and devices.

Risk of injury by improper handling. Injury bycrushing, shearing, cutting, hitting!

CAUTION

Protection during handling and mounting:● Observe the relevant statutory regulations of accident prevention.● Use suitable equipment for mounting and transport.● Avoid jamming and crushing by appropriate measures.● Always use suitable tools. Use special tools if specified.● Use lifting equipment and tools in the correct manner.● Use suitable protective equipment (hard hat, safety goggles, safety

shoes, safety gloves, for example).● Do not stand under hanging loads.● Immediately clean up any spilled liquids from the floor due to the risk of

falling!

Risk of burns, risk of injury due to hotsurfaces of the motor-pump-unit.

CAUTION

● Do only touch surfaces of the motor-pump-unit with protective gloves ordo not work on hot surfaces. During or after operation, temperatures canbe over 60°C (140°F).

● Before accessing, let the motor-pump-unit cool down for a sufficientlylong time.

● Observe the protective measures of the plant manufacturer.

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Safety instructions



Health risk due to contact with hydraulic fluid.CAUTION

Impairment to health, like eye injury, skin injury and contamination possible:● Avoid contact with hydraulic oil.● Observe the safety instructions of the manufacturer when working with

hydraulic oil.● Use personal protective equipment (e.g. safety glasses, safety shoes,

protective gloves, suitable working clothes).● Consult a doctor if hydraulic oil contacts your eyes or bloodstream or is

swallowed.

Risk of injury, danger of slipping due togreasy surfaces.

CAUTION

● Make the danger zone safe and designate it as such.● Use an oil binding agent to contain spilled or excess hydraulic fluid.● Use personal protective equipment (e.g. safety shoes, protective gloves,

suitable working clothes, ...).● Remove and dispose of the contaminated oil binding agent in

accordance with the national regulations.

Risk of injury due to uncontrolled dischargehydraulic fluid on the motor-pump unit.

CAUTION

● Immediately switch-off the machine in case of an error (emergency stopswitch).

● Identify and remove the reason for leakage.● Do not try to stop or to seal the leakage or the oil jet with a cloth.● Avoid contact with high pressure oil discharge.● Perform regular visual inspections on the motor-pump unit and all oil-

bearing components.

Risk of injury by improper handling ofbatteries

CAUTION

Batteries consist of active chemicals in a solid housing. Therefore, improperhandling can cause injury or property damage:● Do not attempt to reactivate low batteries by heating or other methods

(risk of explosion and cauterization).● Do not attempt to recharge the batteries as this may cause leakage or

explosion.● Do not throw batteries into open flames.● Do not dismantle batteries.● When replacing the battery/batteries, do not damage the electrical parts

installed in the devices.● Only use the battery types specified for the product.


Safety instructions


Environmental protection and disposal! The batteries contained inthe product are considered dangerous goods during land, air, andsea transport (risk of explosion) in the sense of the legalregulations. Dispose of used batteries separately from otherwaste. Observe the national regulations of your country.

2.7 Obligations of the machine end-userThe machine end-user of products of Bosch Rexroth AG must provide theirpersonnel with training for the following topics on a regular basis:● Observance and use of operating instructions and the applicable legal

provisions.● Intended operation of the product.● Observance of the instructions of the factory security offices and the

machine end-user's working instructions.● Behavior in case of an emergency.

Bosch Rexorth AG offers training support in specific fields. Youcan find an overview of training contents on the Internet underhttp://www.boschrexroth.de/didactic.

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Safety instructions



3 General notes on material damage and product dam‐age

Material damage due to improper handling,pollution or cleaning!

NOTICE

Improper Handling● The motor-pump-unit may only be used according to the section "Appro‐

priate Use".● Do not apply excessive force or damage the function relevant surfaces

such as mounting surfaces and hydraulic connections.● Mixing of hydraulic fluids

Do not mix different types of hydraulic oils from the same manufacturersor oils from multiple manufacturers.

Premature wear and malfunctions due to pollution by liquids and foreign bod‐ies.● Pay attention to cleanliness during assembly to prevent foreign objects

to contaminate the hydraulic fluid. Foreign objects in the hydraulic fluidcan cause excessive wear and malfunctions on the motor-pump unit.

● Ensure clean and chipless connections, hydraulic lines and mountingparts (e.g. measuring devices).

● Use residue-free industrial wipes to remove lubricants and other heavycontamination.

● Prior to start up ensure that all hydraulical and mechanical connectionsare securely connected.

● Perform cleaning procedures on the motor-pump-unit only with locked-out hydraulic connections.

● Use a filter while filling the hydraulic fluid to minimize the sediment pollu‐tion and water in the system.

Improper cleaning● Secure all apertures with suitable protective caps or protective screwed

connections to prevent penetration by cleaning agents.● Check fit and seating of all sealings and fasteners of electrical connec‐

tions to prevent penetration by cleaning agents.● Do not use aggressive cleaning agents. Clean the motor-pump-unit with

a suitable cleaning fluid.● Do not use high pressure washer for cleaning.Operation with insufficient hydraulic fluid● The motor-pump-unit can be damaged or destroyed. Heed the specifica‐

tions of the machine manufacturer about "Control of hydraulic fluid" andthe specified corrective actions to the test result.

Leakage or spillage of hydraulic fluid.● Use an oil binding agent to bind and contain spilled hydraulic fluid.● Place a catch pan under the motor-pump-unit when filling or discharging

hydraulic fluid.● Please observe the details in the safety data sheet of hydraulic fluid and

the regulations of the machine manufacturer.


General notes on material damage and product damage


4 Symbols and their useAction symbols Use "action symbols" to commission and to operate the devices and the soft‐

ware.The action symbols indicate the following:● The symbol illustrates the action to be carried out.● The arrow indicates the specific position the action is to be applied to.● The numbers indicate the order in which subsequent actions have to be

executed. There are six steps per screen shot at most.

Fig. 4-1: Combinations of action symbols

Action symbol Meaning

Left-click: Click using the left mouse button.

Double click: Double click using the left mouse button.

Right-click: Click using the right mouse button.

Drag: Click the left mouse button and keep it pressed. Movethe mouse to the target position (continued in the next sym‐bol).

Drop: Release the mouse button at the target position.


Symbols and their use


Action symbol Meaning

Text input: Enter your text.

Note: Note or compare information, e.g. a results list, informa‐tion on the device display, comparison of input data with con‐nected devices.

Tab. 4-1: Action symbols

Fig. 4-2: BulletsThe bullets sub-divide steps or are used as markers (e.g. to describe differentareas in a screen shot).

Other symbols Symbol Meaning

Information

Mail

Internet address

Question

Note, warning

Tab. 4-2: Other symbols

Keyboard symbols Symbol Name

Cancel

Alternative

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Symbol Name

Paste

Enter

Delete

Space

Arrow left

Arrow up

Arrow right

Arrow down

Ctrl

Shift

Tab. 4-3: Keyboard symbols




5 Introduction and basic principles of IMC5.1 Application type

The IMC software/parameter file is part of the SvP 7020 product range, spe‐cifically designed for injection molding and blow molding applications with p/Qcontrol function.

Fig. 5-1: Block diagram, p/Q control (IMC)

5.2 System requirements/componentsHardware Sytronix unit (motor-pump group), hydraulic cylinder, power section (HCS01/

HCS02/HCS03/HMS01/HMS02), control section (CSH02.1 and CSB02.1),pressure sensor for pressure control.

● The direction of rotation for pressure increase is always pos‐itive.

● Pressure values always refer to the atmospheric pressure.This applies to both pump data and sensor values.


Introduction and basic principles of IMC


Firmware Required firmware:FWA-INDRV*-MPx-20VRS-D5-1-SYX-TFFWA-INDRV*-MPx-20VRS-D5-1-SYX-MLFWA-INDRV*-MPx-20VRS-D5-1-SYX-MA

Tools Engineering PC with IndraWorks MLD/D/Ds 14V24Technology function/software IMC02V14

Functional package/license forIndraMotion MLD

Since the IMC software/parameter file is based on an integrated PLC, thesystem requires a firmware with a functional package for MLD. There are thefollowing options:● “TF“ for using the self-contained IMC function● “ML“ for using the self-contained IMC function as well as IMC-Lib to im‐

plement your own additional functions.● “MA“ for high functionality (in combination with specific technology func‐

tions).The user has to specify the correct firmware package for the required func‐tionality.

In urgent cases, functional packages may be subsequently activa‐ted via IndraWorks. After an unlicensed function has been activa‐ted, the corresponding license has to be ordered from Bosch sothat the function can be rightfully used.

To operate the Sytronix 7020 systems, use the drive firmwarewith the "SYX" expansion package.

Fig. 5-2: Activating MLDUsing the IMC function Bosch Rexroth service and application engineers can expand the functionali‐

ty on their own. To this end, the IMC library is available.

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In this case, the IMC function has to be included as a library in the MLD pro‐gram. The respective functions then have to be called in the correspondingtasks:

Fig. 5-3: Program calls required when using the library for IMC02VRS.

As of version IMC02V14, the “t50ms call” is no longer provided.

Fig. 5-4: Program calls required when using the library for IMC02VRS






To use the IndraWorks dialogs for operating and diagnosing theSytronix function also when employing the library, the file name ofthe IndraWorks/MLD project has to begin with the following char‐acters:● IMC02VRS: "FWS_MLDSYx_IMC_02"

In the case of additional MLD programming, it is recommendedusing the exemplary project "FWS_MLDSYx_IMC_02VRS_Exam‐ple.xiwp" as a basis. Thereby, the correct name and required taskcalls have already been implemented.

This ensures that the IndraWorks dialogs can be operated and the correcttask configuration is available, and that the correct programs are included atthe right places.

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System function

Fig. 5-7: System function

5.3 Electrical system characteristicsCombinations of firmware, control

section, master communicationAccording to the application, the characteristics of control section options andmaster communication used have an influence on the firmware and the avail‐able operation modes. CSH (Advanced) and CSB (Basic) differ in perform‐ance, function and configuration. The tables below show the supported com‐binations:




IndraDrive C, IndraDrive M

Function/application Operation mode

Firm

war

e

Con

trol s

ectio

n

Com

mun

icat

ion

Mot

or e

ncod

er (m

otor

con

trol)

Clo

sed-

loop

con

trol

Pres

sure

con

trol

Ope

n-lo

op fl

ow ra

te c

ontro

l

Anal

og M

/S m

ode

Velo

city

con

trol

MPB-20 CSB02.1A ET EC NN xx xx Multi-Ethernet Closed-looprecommen‐ded, open-loop possi‐ble (restric‐ted dynam‐

ics)

pQ ✓ ✓ ✓

PB PROFIBUS®

CN CANopen®

MPB-20 CSB02.1B ET EC NN xx xx Multi-Ethernet ✓

PB PROFIBUS®

CN CANopen®

xx DA Analog

NN NN Analog

MPC-20 CSH02.1B CC EC NN xx DA Analog

ET xx Multi-Ethernet

PB PROFIBUS®

CN CANopen®

S3 EC xx xx DA Analog

xx Sercos®

Tab. 5-1: IMC device configuration (IndraDrive C, IndraDrive M)

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IndraDrive Cs (HCS01)

Function/application Operation mode

Firm

war

e

Driv

e co

ntro

ller

Com

mun

icat

ion

Mot

or e

ncod

er (m

otor

con

trol)

Clo

sed-

loop

con

trol

Pres

sure

con

trol

Ope

n-lo

op fl

ow ra

te c

ontro

l

Anal

og M

/S m

ode

Velo

city

con

trol

MPC-20 HCS01.1E-W00**-A-0*-

A-CC EC NN xx Sercos® Closed-loop recommended,open-loop possible (restricted

dynamics)

pQ ✓ ✓ ✓

ET Multi-Ethernet

PB PROFIBUS®

CN CANopen®

DA* Analog ✓

MPC-20 HCS01.1E-W00**-A-0*-

A-ET EC NN xx Multi-Ethernet

PB PROFIBUS®

CN CANopen®

DA* Analog ✓

MPB-20 HCS01.1E-W00**-A-0*-

B-ET EC NN xx Multi-Ethernet

PB PROFIBUS®

CN CANopen®

DA* Analog ✓

* At the time the documentation was written, DA option not avail‐able in combination with safety functions. If required, pleaseverify availability.

Tab. 5-2: IMC device configuration (IndraDrive Cs)

5.4 Functional featuresThe system function Injection

Molding Control (IMC02VRS) ischaracterized by the following

functional characteristics:

1. Communication interface and I/Os● Evaluation of pressure sensors via analog input

– Freely scalable analog input scaling (V/bar, ...)– Signal filtering via PT1 filter

● Cyclic command value transmission (p_cmd or Q_cmd) via fieldbus or analog input– Command value filtering for ascent/descent (separate), PT1

filter– Minimum value and soft start function

2. IMC flow rate/pressure control (p/Q)● TA = 1 ms, or 2 ms pressure controller clock (depending on selec‐

ted control section)




● p→Q switching/minimum value generator● Switching between p/Q and speed control● Unipolar controller output limitation (n_pos, n_neg)● Freely definable ramp to limit changes in controller output (acceler‐

ation limit value)● Pressure-dependent switching of integral action time at pressure

controller3. Optional additional functions

● Integrated automatic injection function to optimize overshooting● Leakage compensation● Double pump operation / two-point adjustment with integrated

valve control (cam)● Master/slave operation with „multi-master function“ option, i.e.

mode (master/slave) is switchable during operation– Analog axis linking (speed command value) with commanding

via external control● 2 parameter sets, performance-dependent (power, pressure)● 4 switchable parameter sets

4. Integrated monitoring/protective functions

5.5 Relevant parametersSee chapter 7 "Parameters and diagnostic messages for p/Q control injec‐tion molding (IMC)" on page 119

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6 Commissioning6.1 Establishing the connection to the drive controller6.1.1 General information

Use the IndraWorks software to commission and diagnose IndraDrive devi‐ces. It is possible to use IndraWorks Ds and IndraWorks D/MLD.

The following paragraphs show the drive commissioning steps,exemplified by IndraWorks Ds. The dialogs can look different ifIndraWorks D/MLD is used.

6.1.2 RequirementsThe following components and requirements are needed for Ethernet com‐munication with the drive controller:● IndraDrive device● Suitable firmware● Standard Ethernet cable● Unassigned Ethernet interface at PC or notebook● IndraWorks Ds or IndraWorks D/MLD

6.1.3 Establishing the connectionTo configure the drive in IndraWorks, establish a connection. It can be estab‐lished via an Ethernet connection using an unassigned Ethernet interface atthe drive. The connection can be directly selected when starting IndraWorksDs or using the Tools ▶ Connection selection ▶ Connection selection... menu.The IP address can be changed using the control panel of the drive control‐ler, or via IndraWorks.

If the control is connected to the company network, observe yournetwork administrator’s instructions.

Ethernet connection After IndraWorks was started, the connection selection dialog opens. Usingthe Network search tab, all devices that are in the same network will befound, independent of their IP and computer configuration. Devices with an IPconfiguration outside of the subnet used will also be found.

It is not possible to search across network boundaries (router).


Commissioning


Fig. 6-1: Network search

Fig. 6-2: Establishing the connection in the network search

If the "Identify" column is ticked, the display of the selected driveflashes.

If the network search was successful, but the IP address does not match, it isimpossible to establish communication. IndraWorks then displays the devicein red.

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Commissioning



In this case, there are two options after having clicked on "Connect"

Fig. 6-3: IP address does not match1. Extending the computer IP address (e.g., in case servicing is required).

IndraWorks automatically adds a matching IP address in the computerto facilitate communication with the devices. The address will be auto‐matically deleted, if the check box for "Restore old settings" has beenactivated and IndraWorks is closed, or after a system restart

Fig. 6-4: Extend IP address settings2. Changing the drive address (e.g., initial commissioning). Using the "Se‐

tIP" SIP service, the IP address can be changed in the drive remotely.IndraWorks suggests an IP address suitable for communication with thecomputer. Alternatively, a specific IP address can be assigned.


Commissioning


Fig. 6-5: Changing the IP configuration

Fig. 6-6: Changing the IP configuration in the deviceAnother option for establishing a TCP/IP connection is to set the addressrange to be browsed in the connection selection dialog on the IP addresssearch tab.

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Commissioning



ⓐ Enter address or rangeFig. 6-7: IndraWorks Ds - establishing connection to drive (TCP/IP connection

using an Ethernet interface)The current IP settings of the drive can be read using the control panel.

IP address range For local networks, IP addresses can be assigned in the following addressranges:● 10.0.0.0 to 10.255.255.255,● 172.16.0.0 to 172.31.255.255 and● 192.168.0.0 to 192.168.255.255Example:IP address: 192.168.0.19Network mask: 255.255.255.0Default gateway: 0.0.0.0

The desired IP address, network mask and default gateway canonly be parameterized in the parameter mode. See below for thedescription of how to switch to the parameter mode using the con‐trol panel.

Setting the IP address using thecontrol panel

To set the IP address using the control panel, proceed as follows:1. Switch on the control voltage of the drive controller.2. Press the key on the control panel.3. Select "Ethernet" with the / keys and confirm your selection with the

key.4. With the / keys, select the connected interface you would like to

configure (e.g., X22)5. Select the address you would like to configure or verify

● IP address


Commissioning


● MAC address● Gateway address● Network mask (subnet mask)

The individual octets are applied by pressing the key. You canalways get back using the key.

6. Switch the control voltage of the drive controller off and back on so thatthe parameterization of the desired IP address, network mask and de‐fault gateway takes effect. From firmware MPx18 and above, the param‐eterization is directly applied without restart.

6.2 Loading IMC project6.2.1 Software/parameter file (*.par)

To access the IMC dialog, it is first of all necessary to load the software/parameter file. The IMC software/parameter file has already been loaded inits condition as supplied or is available as a ready-made solution (loadablecompiled MLD project) in the form of a parameter file(FWS_MLDSYx_IMC_02Vxx_EN).No PLC programming knowledge is required, because the complete IMCfunction can be operated via the dialogs in IndraWorks Ds.To do this, the following steps have to be executed:

1. To have the active MLD program and its status displayed, click "Projectinfo" under the MLD branch in IndraWorks.

2. Here, the loaded software/parameter file can be verified and it can bemade sure that the program is running ("RUN" status).

3. If necessary, a new program can be loaded (as a software/parameterfile) via "Load project...".

4. When the IMC project name is displayed, the "SYTRONIX 7020(IMC02)" dialog appears in the project tree.

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Commissioning



Fig. 6-8: Project information

6.3 Configuring IndraDrive6.3.1 Master communication

Connection to the control ● Connection to the control can be established via the communication in‐terfaces available in the drive. The following interface types have to bedistinguished:– Analog/parallel interface– Digital field buses (PROFIBUS®, CANopen® etc.)– Multi-Ethernet (EtherNet/IPTM, Sercos®, PROFINET®, EtherCAT®)

● For the data exchange (command/actual values) with the drive, the driveparameters defined for the IMC02 function are exchanged via the fieldbus interface (see fig. 6-13 "Communication interface with external con‐trol" on page 39)

● The IMC02 function is configured via the defined drive parameters, see:chapter 7 "Parameters and diagnostic messages for p/Q control injec‐tion molding (IMC)" on page 119

All field buses available to IndraDrive are supported:


Commissioning


Fig. 6-9: Connection to the control

It is recommended that the master communication be activatedonly after the IndraDrive and the technology function was config‐ured. Repeatedly switching the phases of the drive state machine,which is required for commissioning, causes the machine com‐missioning under an active field bus to be delayed.

The basic configurations are selected by loading the default settings for theselected interface.

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Commissioning



Fig. 6-10: Loading the basic settings


Commissioning


Fig. 6-11: Loading the default values for field bus interface

The master communication settings can be selected inIndraWorks directly in the "Master communication" task, see "Se‐lecting and setting the master communication: " on page 40

The selected communication interface is displayed in the main dialog:

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Commissioning



Fig. 6-12: Field bus interface selectedThe process data of the communication with external controls are displayedin the following figure:

Fig. 6-13: Communication interface with external controlAfter the “Load IMC basic setting” button was pressed, the selected real-timeinput and real-time output are automatically set for the relevant communica‐tion type (EtherNet/IPTM, PROFINET®, PROFIBUS®).


Commissioning


Fig. 6-14: AT protocol settings (SvP 7020 → PLC)

Fig. 6-15: MDT protocol settings (PLC → SvP 7020)The master communication settings differ depending on the selected fieldbus. For field buses of the highest relevance for the technology function, pa‐rameterization examples of an injection molding application in the "velocitycontrol" mode are given below.

Cyclically transmitted feedback values can be very noisy, like thevelocity feedback value (S‑0‑0040) due to the encoder signal. Toprovide a usable signal to the higher-level control, the display oftwo selectable feedback values (velocities, accelerations, tor‐ques...) can be smoothed in IndraDrive using the average valuefilter for display. Internally, IndraDrive continues computing withthe non-filtered values.

Fig. 6-16: Average value filter displaySelecting and setting the master

communication:

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Commissioning



PROFIBUS® The commissioning manual "IndraDrive with PROFIBUS® - Beispiel mit Sie‐mens SIMATIC S7" (R911341340 - only available in German) describes indetail how to configure the control and IndraDrive. The paragraphs below de‐scribe the most important configuration steps on the IndraDrive side.1. Activate field bus, if necessary (P‑0‑4089.0.1 = 16)

Fig. 6-17: Activating the field busRestart (C6400) required!

2. Set drive address (P‑0‑4025)


Commissioning


Fig. 6-18: Setting the slave address3. Activate profile type "freely configurable mode" (P‑0‑4084 = 0xFFFE)

Fig. 6-19: Activating the freely configurable mode

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Commissioning



Operation modes and cyclic data are preconfigured by activating theprofile type. Subsequently, they have to be adjusted (recommended:use “Load IMC basic setting”).

4. Configuring cyclic feedback values (AT)

Fig. 6-20: Real-time input (AT)● P‑0‑4078 (Field bus: Status word); length: 2 bytes; decimal places:

0; unit: -● P‑0‑1410 (PLC output WORD0 AT %QB0); length: 2 bytes; deci‐

mal places: 0; unit: -● Velocity feedback value (S‑0‑0040); length: 4 bytes; decimal pla‐

ces: typically 4; unit: typically rpm● S‑0‑0813 (system pressure); length: 4 bytes; decimal places: typi‐

cally 3; unit: typically bar● S‑0‑0390 (diagnostic message number); length: 4 bytes; decimal

places: 0; unit: -● P‑0‑1411 (PLC output WORD1 AT %QB2); length: 2 bytes; deci‐

mal places: 0; unit: -5. Configuring cyclic command values (MDT)

Fig. 6-21: Real-time output (MDT)● P‑0‑4077 (field bus: control word); length: 2 bytes; decimal places:

0; unit: -● P‑0‑1390 (PLC input WORD0 AT %IB0); length: 2 bytes; decimal

places: 0; unit: -● P‑0‑1377 (PLC Global Register G7); length: 4 bytes; decimal pla‐

ces: 0; unit: -● S‑0‑0800 (Pressure command value); length: 4 bytes; decimal pla‐

ces: typically 3; unit: typically barThe sum of command value bytes to be cyclically transmitted is dis‐played in "Field bus: Length of cyclic command value data channel"(P‑0‑4071). For an operable bus communication, the same length has tobe set on the control side.

6. Configuring operation modes● Primary operation mode: Velocity control; S‑0‑0032 =

0b0000.0000.0000.0010


Commissioning


PROFINET® The commissioning manual "IndraDrive mit PROFINET® - Beispiel mit Sie‐mens SIMATIC S7" (IndraDrive with PROFINET® - Example with SiemensSIMATIC S7) (R911341342) describes in detail how to configure the controland IndraDrive. The paragraphs below describe the most important configu‐ration steps on the IndraDrive side.1. Activate field bus (P‑0‑4089.0.1 = 4)

Fig. 6-22: Field bus start dialog

Restart (C6400) required!2. The slave address (P‑0‑4025) can be set optionally. The communication

is IP-based and configured with the "device naming" on the higher-levelcontrol

3. Activate profile type "freely configurable mode" (P‑0‑4084 = 0xFFFE)

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Commissioning



Fig. 6-23: Activating the freely configurable modeOperation modes and cyclic data are preconfigured by activating theprofile type. Subsequently, they have to be adjusted (recommended:use “Load IMC basic setting”).








mal places: 0; unit: -


Commissioning


5. Configuring cyclic command values (MDT)







0b0000.0000.0000.0010Activate Ethernet/IPTM The paragraphs below describe the most important configuration steps on the

IndraDrive side.1. Activate field bus (P‑0‑4089.0.1 = 3)

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Commissioning



Fig. 6-26: Activating EtherNet/IPTM

Restart (C6400) required!2. The slave address (P‑0‑4025) can be set optionally. The communication

is IP-based and configured on the higher-level control3. Activate profile type "freely configurable mode" (P‑0‑4084 = 0xFFFE)


Commissioning


Fig. 6-27: Freely configurable modeOperation modes and cyclic data are preconfigured by activating theprofile type. Subsequently, they have to be adjusted (recommended:use “Load IMC basic setting”).








mal places: 0; unit: -

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Commissioning



5. Configuring cyclic command values (MDT)







0b0000.0000.0000.0010EtherCAT® (SoE) The Commissioning Manual "IndraDrive with EtherCAT® - Example with

Beckhoff TwinCAT®" (R911341345) describes in detail how to configure thecontrol and IndraDrive. Since the configuration is carried out almost exclu‐sively on the control side, only the master communication needs to be activa‐ted in IndraDrive.1. Activate field bus (P‑0‑4089.0.1 = 5)


Commissioning


Fig. 6-30: Activating EtherCAT® (SoE)Restart (C6400) required!

2. Profile type "Servo drive profile" (P‑0‑4084 = 0x0002)3. Configure cyclic feedback values (AT) (on control side)

● P‑0‑4078, (Field bus: Status word); Length: 2 bytes; decimal pla‐ces: 0; unit: -

● P‑0‑1410 (PLC output WORD0 AT %QB0); length: 2 bytes; deci‐mal places: 0; unit: -

● Velocity feedback value (S‑0‑0040); length: 4 bytes; decimal pla‐ces: typically 4; unit: typically rpm

● S‑0‑0813 (system pressure); length: 4 bytes; decimal places: typi‐cally 3; unit: typically bar

● S‑0‑0390 (diagnostic message number); length: 4 bytes; decimalplaces: 0; unit: -


4. Configure cyclic command values (MDT) (on control side)● P‑0‑4077 (Field bus: Control word); Length: 2 bytes; decimal pla‐

ces: 0; unit: -● P‑0‑1390 (PLC input WORD0 AT %IB0); length: 2 bytes; decimal



ces: typically 3; unit: typically bar

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Commissioning



The sum of command value bytes to be cyclically transmitted is dis‐played in "Field bus: Length of cyclic command value data channel"(P‑0‑4071). For an operable bus communication, the same length has tobe set on the control side.


0b0000.0000.0000.0010EtherCAT® (CoE) 1. Activate field bus (P‑0‑4089.0.1 = 8)

Fig. 6-31: Activating EtherCAT® (CoE)Restart (C6400) required!

2. Profile type "Servo drive profile" (P‑0‑4084 = 0x0402)3. Configure cyclic feedback values (AT) (on control side)

● P‑0‑4078, (Field bus: Status word); Length: 2 bytes; decimal pla‐ces: 0; unit: -






4. Configure cyclic command values (MDT) (on control side)


Commissioning


● P‑0‑4077 (Field bus: Control word); Length: 2 bytes; decimal pla‐ces: 0; unit: -

● P‑0‑1390 (PLC input WORD0 AT %IB0); length: 2 bytes; decimalplaces: 0; unit: -

● P‑0‑1377 (PLC Global Register G7); length: 4 bytes; decimal pla‐ces: 0; unit: -

● S‑0‑0800 (Pressure command value); length: 4 bytes; decimal pla‐ces: typically 3; unit: typically bar

The sum of command value bytes to be cyclically transmitted is dis‐played in "Field bus: Length of cyclic command value data channel"(P‑0‑4071). For an operable bus communication, the same length has tobe set on the control side.


0b0000.0000.0000.0010Sercos® Since the configuration is carried out almost exclusively on the control side,

only the master communication needs to be activated in IndraDrive.1. Activate field bus (P‑0‑4089.0.1 = 6)

Fig. 6-32: Activate Sercos®Restart (C6400) required!

2. Profile type "FSP Drive (Sercos® profile)" (P‑0‑4084 = 0x0102)3. Configure cyclic feedback values (AT) (on control side)

● P‑0‑4078, (Field bus: Status word); length: 2 bytes; decimal places:0; unit: -


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Commissioning







4. Configure cyclic command values (MDT) (on control side)● P‑0‑4077 (Field bus: Control word); Length: 2 bytes; decimal pla‐

ces: 0; unit: -● P‑0‑1390 (PLC input WORD0 AT %IB0); length: 2 bytes; decimal





0b0000.0000.0000.0010


Commissioning


6.4 IMC commissioning6.4.1 Overview

Dialogs specifically developed for the technology function are available to fa‐cilitate commissioning. The introductory overview dialog is started using the"SYTRONIX 7020 (IMC02)" menu item under the "MLD" branch in theIndraWorks tree:

Fig. 6-33: Start dialog of the IMC software/parameter fileThe dialog comprises four functional areas which will be explained in the fol‐lowing:

1. I/O configuration:Configuration of the input and output signals for IndraDrive

2. IMC controller:IMC controller configuration

3. Diagnostics:Status display and output of warnings/errors

4. Configuration:Information and settings of the complete system (hardware and soft‐ware)

These four functions can be displayed using IndraWorks.

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Commissioning



Fig. 6-34: Functional area of the start dialog

6.4.2 Initial commissioning for IMCThe following points are to be considered/completed before operation:● General drive commissioning (operation in velocity control possible)

In order to prevent damage to the pump,it has to be checked before setting ofthe error reaction to torque disable inevery individual case whether backwardrotation of the pump is admissible. If not,mechanical precautions are to be takenin order to prevent it (check valve).

WARNING

The direction of rotation causing thepressure increase must always be posi‐tive. Otherwise, operation is not possibleand/or the pump may be damaged.

WARNING

If the direction of rotation is not positive, change the weighting settings/signs of the velocity data.

Loading the basic settings (defaultvalues for IMC)

The function for loading the basic settings is called by clicking the “Loadbasic settings” push button.


Commissioning



Fig. 6-36: IMC basic settingsThe dialog consists of 4 areas. To the right, the Load IMC basic settings but‐ton is provided:1. Load basic parameters: here, the drive parameters are set to factory de‐

fault values, without master communication parameters and withoutMLD parameters.

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Commissioning



2. IMC basic settings, selection of the communication interface (analog orfield bus).

Use the correct hardware configuration/control unit!

Communication/interfaceDepending on the hardware/control unit type, two types of interfaces(analog, field bus/Ethernet) are available. According to the recognizedhardware, one of the following interfaces can be set when the dialog isopened. Configure the selection by clicking on “Load default values”.● Analog interface● Field bus interface

– Sercos®– EtherCAT® (SoE + CoE)– PROFINET®– EtherNet/IPTM

– PROFIBUS®– CANopen®

3. Configuration analog input: here, the pressure sensor input is configured4. Configuration of the motor-pump group and setting of the parameters for

the control loop according to pump and motor typeMotor/pump groupThe pump type used can be selected. The IMC02 functionality contains therequired pump data.

Pump data of the selected type cannot be changed. In this case,select “other pump”.

IMC Load the basic settings on the right side of the dialog - load basic andexecutable parameter settings.Basic configuration/interfacesThe basic communication settings are loaded.Protective/monitoring functionThe basic settings of the protective/monitoring function are loaded.Controller parametersFor the related controller parameters such as velocity controller, PID control‐ler of the p/Q control, default values are loaded using the “Load IMC basicsettings” interface. With these settings, the IMC02 functionality usually runssmoothly for most hydraulic systems.● Configuring/adjusting the pressure sensor evaluation

→ see chapter 6.4.3 "Communication interface and I/O configuration" onpage 58

● Configuring/adjusting the interface for external control→ see chapter 6.4.3 "Communication interface and I/O configuration" onpage 58

● Configuring/adjusting the protective function→ see chapter 6.5 "Configuring the protective functions" on page 96


Commissioning


6.4.3 Communication interface and I/O configuration1) Configuration of the pressure sensor interface (CSH control section)

Fig. 6-37: Pressure sensor configuration1. Via the pressure sensor, the pressure control loop is closed.

It is recommended that pressure transducer HM20-2X be used (datasheet RE 30272).

2. Use a pressure sensor with a voltage output within the range of 0 to 10V or, depending on the control unit variant, use a current sensor withinthe range of 4 mA to 20 mA to acquire the pressure.A voltage sensor with offset for the actual value output or a current sen‐sor is recommended in order that the cable break detection function canbe used.

The pressure sensor is connected to X32, X35 or the DA option X38 accord‐ing to the table below. The measuring cables are to be shielded together.

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Front view(example)

Connection point Shield Signal - Signal +

Pressure sensorconnection point

Connection ofshielded measur‐

ing cables thatare shielded to‐

gether

Connection of thereference signal

Connection of thesignal line

X32Analog inputs

X32.1 X32.2I_a_1-

X32.3I_a_1+

X35Digital inputs andoutputs; analoginputs (current/voltage); analogoutputs (voltage)

X35.1.3 X35.1.2I_a_2-I_a_3-

X35.1.1I_a_2+I_a_3+

X38*Analog inputs/

outputs

X38.2.3 X38.2.2I_a_2-

X38.2.1I_a_2+

X38*Analog inputs/

outputs

X38.2.3 X38.2.5I_a_1-

X38.2.4I_a_1+

* Optional connection point; in the sample illustration, the option‐al connection points are shown with a gray background

Tab. 6-1: CSH02 connection pointsWith pressure transducers of series HM20-2X, the correct type can be selec‐ted in the drop-down field (see pressure sensor data sheet, RE 30272).


Commissioning


Fig. 6-38: Selection of the voltage sensor HM20-2X/...If the type is not contained in the drop-down field, the user has to enter itmanually.

Fig. 6-39: Selection of another voltage sensorUpon selection of the interfaces X35 or X38, you can also select and config‐ure a current sensor applying the same procedure.

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2) Configuration of the pressure sensor interface (CSB control section)Front view(example)





gether



X32Analog inputs

X32.1 X32.2I_a_1-

X32.3I_a_1+

X351)

Digital inputs andoutputs; analoginputs (current/voltage); analogoutputs (voltage)

X35.1.3 X35.1.2I_a_2-I_a_3-

X35.1.1I_a_2+I_a_3+

X38*1)

Analog inputs/outputs

X38.2.3 X38.2.2I_a_2-

X38.2.1I_a_2+

X38*1)

Analog inputs/outputs

X38.2.3 X38.2.5I_a_1-

X38.2.4I_a_1+

1) only CSB02.xB* Optional connection point; in the sample illustration, the option‐

al connection points are shown with a gray backgroundTab. 6-2: Connection points CSB02


Commissioning


Fig. 6-40: Selection of the pressure transducer HM20-2X/…If the type is not contained in the drop-down field, the user has to enter itmanually.

Fig. 6-41: Selection of another voltage sensorUpon selection of the interfaces X35 or X38, you can also select and config‐ure a current sensor applying the same procedure.

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3) Configuration of the pressure sensor interface HCS01Front view(example)





gether



X32Analog inputs

X32.1 X32.2 X32.3

X38*Analog inputs/

outputs

X38.2.3 X38.2.2 X38.2.1

X38*Analog inputs/

outputs

X38.2.3 X38.2.5 X38.2.4

* Optional connection point (DA option)Tab. 6-3: Connection points HCS01

Fig. 6-42: Selection of the pressure transducer HM20-2X/…If the type is not contained in the drop-down field, the user has to enter itmanually.


Commissioning


Fig. 6-43: Selection of another voltage sensorUpon selection of the interface X38, you can also select and configure a cur‐rent sensor applying the same procedure.

4) Analog interface for the external controlThe basic configurations are selected by loading the default settings (see"Loading the basic settings (default values for IMC)" on page 55) for the se‐lected interface.


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Fig. 6-45: Load default values for analog interfaceAfter this step, the analog communication is set

Fig. 6-46: Analog interface selectedCSB, CSH, HCS01 In case of CSH02 and CSB02, the analog input and output signals are con‐

nected via ports X32, X35 and via X38 on the DA option and via ports X32,X37 and X38 in case of HCS01.The command and actual values are set (assignment of the inputs and out‐puts to the correct parameters) by loading the basic configuration. See"Loading the basic settings (default values for IMC)" on page 55.


Commissioning


Fig. 6-47: Command value input

Fig. 6-48: Settings for command value input

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Fig. 6-49: Settings for actual value output

Fig. 6-50: Settings for actual value output


Commissioning


Pin Function Ident number Bit

X31 1 Drive enable P‑0‑4028 15

X31 2 Parameter SET selection P‑0‑1390 14

X31 3 Parameter SET selection P‑0‑1390 15

X31 4 Master/slave switching P‑0‑1390 0

X31 5 Enable injection P‑0‑1390 8

X31 6 Clearing errors S‑0‑0099 0

X32 1 Shield/ground

X32 2 Pressure sensor (analog input -) S‑0‑0813

X32 3 Pressure sensor (analog input +) S‑0‑0813

X35 1.7 Malfunction P‑0‑0115 13

X35 1.8 Double pump/2-point switching P‑0‑1411 0

Tab. 6-4: Basic settings of digital I/Os

Fig. 6-51: Basic settings taking the example of IndraDrive with CSH controlsection

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Commissioning



6.4.4 IMC controller – Parameter settingIntroduction and overview

Activation of the pressure control/flow control

With an MLD that has already been started or directly after its start (parame‐terization of the starting behavior with P‑0‑1367, and/or manual start withP‑0‑1350; see also application description MLD), the function including its rel‐evant parameters are initialized. The actual process control is activated/enabled using P‑0‑1390; bit 0.To successfully enable the p/Q control, the drive has to be switched to AFfirst via the master communication or via a digital input. Otherwise, bit 10 willbe set in the status word P‑0‑1410 in case of activation via P‑0‑1390, bit 0,and no pressure control takes place.Pressure control can also be directly activated by switching on drive enable.The pressure control/flow control starts immediately without P‑0‑1390, bit 0having to be set. This has to be configured by means of P‑0‑1370; bit 10.As long as the MLD is running, bit 0 in status word P‑0‑1410 is used to signalthat pressure control is active.

In case of successful activation of the pressure control, via thedrive, MLD gets control and the system is internally switched tothe velocity control mode.

Deactivation of the pressure con‐troller

The pressure control is switched off by means of P‑0‑1390; bit 0 = 0 and thedrive is stopped. The control is given back to the master communication andthe preset operation mode is re-activated. When enabling the pressure con‐trol via controller enable (P‑0‑1370; bit 10 = 1), disable the pressure controlby removing the controller enable.

By removing the drive enable, the pressure control is also deacti‐vated and the control is given back to the master communication.

Pressure control The pressure control specifies the pump speed in P‑0‑0690 so that the com‐mand pressure specified in S‑0‑0800 is reached and/or maintained.

Closed-loop pressure control/(open/closed-loop) flow control

Closed-loop flow control is realized by limiting the maximum pump speed. Ifthe speed provided by the pump controller falls below the limit P‑0‑1377, flowcontrol is deactivated and the pressure controller assumes controlling.


Commissioning


1) The basic IMC controller structure and the related parameters are shown in the followingillustration:

Fig. 6-52: Control structure IMC controllerThe related dialog window for the controller:

Fig. 6-53: IndraWorks dialog IMC controller1) The filter settings for the pressure command value (p_command) are thefollowing:● P‑0‑1384, PT1 command value filter, filter time constant, ascent, [ms]● P‑0‑1385, PT1 command value filter, filter time constant, descent, [ms]

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2) The following parameters apply to the IMC controller:● P‑0‑1373, IMC control: P-gain, [rpm/bar]● P‑0‑1374, I-integral action time, [ms]● P‑0‑1375, IMC control: D-gain/disturbance observer factor, [rpm/(bar/s)]3) The following parameters show the current speed limitations of the soft‐ware/parameter file:● P‑0‑1289, Effective max. velocity limitation, [rpm]● P‑0‑1290, Effective min. velocity limitation, [rpm]●4) The settings of the acceleration ramp for the pump speed are as follows:● P‑0‑1329, Acceleration limitation of pump speed, [rad/s²]● P‑0‑1330, Deceleration limitation of pump speed, [rad/s²]5) Apart from that, the following velocity controller parameters are important:● S‑0‑0100, Velocity controller proportional gain, [Nm/(rad/s)]● S‑0‑0101, Velocity loop integral action time, [ms]● P‑0‑0004, Speed controller smoothing time constant, [µs]

2) Filter settings for the pressure command value (p_command)The parameters P‑0‑1384 and P‑0‑1385 are set according to the oil volumein the system. Usually, the following applies: the higher the corresponding oilvolume for compression in the pipes and cylinders of the system, the higherthe values for P‑0‑1384 and P‑0‑1385 have to be set.● Small oil volume (3 l)

In case of small oil volume (e.g. oil volume < 3 l), P‑0‑1384 (filter timepressure increase) can be set within the range of 20 to 30 ms. P‑0‑1385(filter time pressure drop) can be selected a little bit lower thanP‑0‑1384, within the range of 15 to 25 ms.

● Large oil volume (~6 l)In case of a large oil volume (e.g. ~6 l), P‑0‑1384 and P‑0‑1385 canboth be set within the range of 40~50 ms.

In case of large pressure overshoots in the pressure increase, you can in‐crease P‑0‑1384. With undershoots in the pressure reduction, increaseP‑0‑1385.


Commissioning


Red line: Actual pressure value courses with different settings forP‑0‑1384 and P‑0‑1385

Blue line: Pressure command value developmentFig. 6-54: Filter effect pressure increase/drop

3) Settings IMC controller (PID)The following parameters are relevant for the setting of the IMC controller:● P‑0‑1373, IMC control: P-gain, [rpm/bar]● P‑0‑1374, I-integral action time, [ms]● P‑0‑1375, IMC control: D-gain/disturbance observer factor, [rpm/(bar/s)]

In order to access the parameter, click on the setting of the con‐troller parameters in the IndraWorks overview screen.

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Fig. 6-55: Pressure controller settingsThe dialog for setting the IMC controller can be called by clicking on the high‐lighted symbol of the configuration tool.

Fig. 6-56: Pressure controller dialog settingsSet P-gain (P‑0‑1373)


Commissioning


The P-gain (P‑0‑1373) can generally be set to a value in the range from 10 to30 [rpm/bar], depending on the compression oil volume in the pipes and cyl‐inders of the system.

With a small oil volume, only a small P-gain is possible! If theovershoot is too high or if vibrations occur, the P-gain must be re‐duced in increments of 5.

Red line: Actual pressure value developments with different settings forP‑0‑1373

Blue line: Pressure command value developmentFig. 6-57: Effect of the adjustment of KpTime constant P‑0‑1374, I-integral action timeThe value must usually lie within the range from 15 to 30 ms.

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Blue line: Pressure command value developmentFig. 6-58: Effect of the adjustment of Tn

If the actual pressure value (S‑0‑0813) shows excessive over‐shoots, particularly during the injection phase, P‑0‑1374 is to beincreased in steps of 5 ms. If the increase in P‑0‑1374 does notsufficiently reduce the overshoots, additional measures are to beimplemented, e.g. switching time constant, see chapter 7.21 "P-0-1311[200]], I - integral action time 2" on page 130 and chap‐ter 7.22 "P-0-1311[201], Filter time constant 2 switching thresh‐old" on page 132.

P‑0‑1375, IMC control: D-gain/disturbance observer factorWhen setting parameter P‑0‑1375, a start value of 0.1 is recommended.

If there are major overshoots in the system, this value is to be in‐creased in steps from 0.1 to 1.0. If the oil volume in the system isvery large, this value may also be greater.


Commissioning



Blue line: Pressure command value developmentFig. 6-59: Effect of the adjustment of Kd

4) Settings of the acceleration ramp for the flow command value (Q_command)With certain pumps, the applied acceleration/deceleration has to be limited inorder to prevent mechanical damage to internal components.On the system side, high acceleration may cause the formation of a localvacuum in the hydraulic fluid as the oil is dynamically not able to follow themovement of the pump rotor. Thus, cavitation may be caused in the system.The pump must work within the limits for acceleration and deceleration whichare specified in the data sheet of the pump.● Maximum positive acceleration of the pump (Pos_Acc_Lim)● Maximum negative deceleration of the pump (Neg_Acc_Lim)

The positive and negative acceleration limits may have differentvalues and must be based on the information in the data sheet ofthe pump. Apart from that, the construction of the suction line hasto be taken into consideration. The construction of the suction lineis an important factor in master/slave applications.

As the limitations for the safe acceleration are system-dependent,the user can use the ramp function freely in the controller struc‐ture. The protective function limits the acceleration on the basis ofthe capability of the pump and the maximum torque of the motoraccording to the data sheet of the pump.

The following parameters are used to set the acceleration limit:● P‑0‑1329, Acceleration limitation of pump speed, [rad/s²]

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● P‑0‑1330, Deceleration limitation of pump speed, [rad/s²]

The acceleration ramp must be set according to the admissiblemaximum values in the data sheet of the pump in order to preventdamage to the pump caused by excessive acceleration!

Fig. 6-60: Setting of the filter for flow/velocityThe acceleration limit is disabled by setting P‑0‑1329 to 0.

5) Parameter setting for the velocity controllerThe velocity controller is configured with the following settings:● S‑0‑0100, Velocity controller proportional gain, [Nm/(rad/s)]● S‑0‑0101, Velocity loop integral action time, [ms]● P‑0‑0004, Speed controller smoothing time constant, [µs]The velocity controller can be set in IndraWorks via the screen for the axiscontrol.


Commissioning


Fig. 6-61: Setting S‑0‑0100, S‑0‑0101

Fig. 6-62: Setting P‑0‑0004For pressure control with the IMC software/parameter file, the following set‐tings are generally recommended:● S‑0‑0100 = P‑0‑0510 * 1000 * 0.4 [kgm2]

– P-0-0510, Rotor inertia– S‑0‑0100, Velocity controller proportional gain

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● S‑0‑0101 = 10 ~ 15 ms– S‑0‑0101, Velocity loop integral action time

● P‑0‑0004 = 800 µs– P‑0‑0004, Speed controller smoothing time constant

● In some cases, a band-stop filter (P‑0‑1122 and P‑0‑1123)has to be used in order to remove a resonance frequency inthe high frequency range (approx. 800 Hz).

● For the motor MSK133 with reluctance torque, S‑0‑0100 hasto be reduced further based on the value specified above.For a system with MSK133, a value of 10 to 20 is recom‐mended for S‑0‑0100.

Parameter setting for the current controlThe control loop of the current control is configured with the following set‐tings:● S‑0‑0106, Current loop proportional gain 1● S‑0‑0107, Current loop integral action time 1

The settings of the current controller are made automatically, us‐ing the MSK motor data. Manual adjustment is not necessary!

6.4.5 Extended settingsOverview

The following extended functions are available:● Double pump operation/two-point control with integrated valve control

(cam)● Master/slave operation i.e. mode (master/slave) is switchable during op‐

eration– Analog axis linking (speed command value) with commanding via

external control● Parameter set switching controller

– Parameter sets, performance-dependent (speed, pressure)– 4 switchable parameter sets

● Integrated automatic injection function to optimize overshooting● Leakage compensation

Double pump operation/two-point control with integrated valve control (cam)

Fig. 6-63: Double pump/variable displacement pump with 2-point operation


Commissioning


Use in applications The functionality serves the reduction of the current consumption in case ofpartial loading of a p/Q-controlled system by reducing the active displace‐ment Vg of the pump. By reducing the active displacement of the pump, thetorque and thus the power consumption of the motor can be reduced.

With this configuration, a combination of smaller motor and drivecan be used for the SYTRONIX solution.

Using the cam to actuate the ad‐justment

To enable this function, set bit 8 to 0 in P‑0‑1370. In P‑0‑1370, bit 9 has to beset to 0 for the 2-point control (in case of variable displacement pumps); fordouble pump systems it has to be set to 1.Use P‑0‑1370; bit 11 to select if the cam state is generated depending on theactual pressure value S‑0‑0813 or the pressure difference S‑0‑0827. Thecam state is output in P‑0‑1411, bit 0.

Fig. 6-64: Hysteresis function of the parameterizable camBy assigning the cam (P‑0‑1411; bit 0) to a digital output of the controller, asecond pump/valve or the swivel angle can be controlled digitally.

Actual pressure value-dependentcam generation

P‑0‑1370, bit 11 = 0: Actual pressure value-dependent cam generationVia a hysteresis function, bit 0 of P‑0‑1411 is formed depending on the pres‐sure feedback value S‑0‑0813. The switching thresholds of the hysteresisfunction have to be specified in P‑0‑1318 and P‑0‑1319.If the pressure feedback value (S‑0‑0813) falls below the pressure set inP‑0‑1319, the bit is set to 0. If the pressure exceeds the value in P‑0‑1318,the bit is set to 1. Otherwise, the current status is not changed.

Control deviation-dependent camgeneration

P‑0‑1370, bit 11 = 1: Control deviation-dependent cam generation Dependingon the amount of the current control difference ( I S‑0‑0827 I ) and the currentactual speed S‑0‑0040, bit 0 is automatically set in P‑0‑1411, Cam statusword.Cam generation:If the amount of the control difference (S‑0‑0827) falls below the pressure dif‐ference set in P‑0‑1319 while the actual speed is below the switching thresh‐old for speed S40 (see below), the bit is set to 0. If the amount of the pres‐sure difference exceeds the value in P‑0‑1318, the bit is set to 1. Otherwise,the current status is not changed. The switching threshold for the speed cor‐responds to the value:

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KFACTOR Factor to adjust the switching speed (<1), input value P‑0‑1326nmax Maximum pump speed according to data sheet

(P‑0‑1389[165])Vg min Minimum displacement V2 of P‑0‑1389[161] (in case of double

pump systems, corresponds to the displacement of the firstpump).

Vg max Maximum displacement (in case of double pump systems, cor‐responds to the displacement of both pumps V1+V2 ofP‑0‑1389[160] + P‑0‑1389[161], or, in case of 2-point control,V1 of P‑0‑1389[160]

Fig. 6-65: Switching threshold of the speedThe switch-on threshold P‑0‑1318 must be greater than the switch-of thresh‐old P‑0‑1319 to ensure the function of hysteresis. If the value in P‑0‑1318,cam, switch-on threshold is smaller than the value in P‑0‑1319, cam, switch-off threshold, it is indicated in the status word P‑0‑1410 in bit 11.If both thresholds (P‑0‑1318, P‑0‑1319) are zero, the generation of the con‐trol difference-dependent cam is disabled and bit 0 in P‑0‑1411, Cam statusword is always 0.The default value of the cam is 0 and is always set during initialization. If thefunction is disabled, bit 0 retains its initial value 0 in P‑0‑1411 Cam statusword.

The pressure difference-dependent bit (P‑0‑1411; bit 0) is refresh‐ed/mapped every 1 ms in case of Advanced control units. In caseof Basic control units, the bit is refreshed/generated every 2 ms.The bit is only generated if pressure control is active. If pressurecontrol is not active (no AF in master mode or active slave mode),the bit can be externally provided via P‑0‑1390; bit 2.

Due to automatic controller adjustment, the controller settings canbe adjusted to the displacement, if required. See "Automatic pa‐rameter set switchover" on page 81

Parameter set switchingThere are two options for changing/adjusting the active pressure controllersetting during operation. There is the option to automatically switch betweentwo settings. Moreover, it is also possible to execute an externally controlledswitching of four parameter sets/settings via P‑0‑1390, Control word. Thetype of switching can be selected by means of P‑0‑1370, Configuration. Bothoptions are explained in the following:

Automatic parameter set switch‐over

To enable the automatic controller switchover, set bit 13 in P‑0‑1370, Config‐uration. Depending on the pressure feedback value (S‑0‑0813, System pres‐sure) or bit 0 in P‑0‑1411, Cam status word, it is possible to switch the con‐troller settings for the P- and the I-term of the pressure controller automatical‐ly: Use P‑0‑1370; bit 12 to select if controller switching is to be executed de‐pending on bit 0 in P‑0‑1411 or by S‑0‑0813, System pressure. UseP‑0‑1410, Process control, status word; bit 12 to display which controller set‐tings are currently active.● Switching depends on P‑0‑1411, Cam status word; bit 0


Commissioning


If P‑0‑1370, Configuration; bit 13/12 = 1/1, controller switching takesplace depending on P‑0‑1411; Cam status word; i.e. depending on dou‐ble pump/swivel angle switching, see chapter chapter "Double pump op‐eration/two-point control with integrated valve control (cam)" on page79. If the bit is set (large volume), the controller settings of P‑0‑1320, P-gain – Set 2 and P‑0‑1321, I-integral action time, set 2 are/become ac‐tive for the P- and I-term of the pressure controller. If bit 0 is not set inP‑0‑1411, the controller settings of P‑0‑1373, IMC control: P-gain andP‑0‑1374, I-integral action time are active again.

● Switching depending on pressure feedback value S‑0‑0813If P‑0‑1370, Configuration; bit 13/12 = 1/0, controller switching takesplace depending on the amount of the active pressure feedback valueS‑0‑0813. If the amount of the actual pressure value exceeds the valueof P‑0‑1322, ParaSet: Switch point, set 2, the controller settings ofP‑0‑1320 and P‑0‑1321 for P- and I-term of the pressure controller be‐come active. If the amount of the active actual process value falls belowthe value of P‑0‑1323, ParaSet: Switch point, set 1, the controller set‐tings of P‑0‑1373, IMC control: P-gain and P‑0‑1374, I-integral actiontime are active again. P‑0‑1410, Status word; bit 12 indicates which con‐troller setting is currently active. If both switch points (P‑0‑1322,P‑0‑1323) are 0, no switching takes place and the settings of P‑0‑1373and P‑0‑1374 are always active.

Fig. 6-66: Hysteresis function with thresholds for automatic switching of thecontroller settings depending on the pressure feedback valueS‑0‑0813

In order to prevent that the controller is switched abruptly, theramp can be used for controller output limitation (P‑0‑1329,P‑0‑1330). Otherwise, controller switching may sporadically resultin jumps of the actuating variable.

Freely selectable parameter sets (4 sets)Use in applications The purpose of this function is the adjustment of the settings of the control

loop to different hydraulic loads and oil volumes present during operation.An optimized parameter set for up to four different hydraulic loads can be de‐fined and selected by the PLC of the machine according to the current status.

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Commissioning



With the default setting of the IMC software/parameter file, onlyone parameter set is used. The related parameters can be direct‐ly set using the dialog of IndraWorks SvP 7020 shown in the fol‐lowing figure. For use of the parameter sets, this functionalitymust first be configured as shown below!

Fig. 6-67: Freely selectable parameter setsEnabling parameter set switching Enabling of freely selectable parameter sets:

If a parameter set (freely selectable set switching) is to be used, the followingdialog has to be enabled using P‑0‑1370; bit 13/12 = 0/1. The function can beenabled in the following dialog

By selecting external parameter set switching in P‑0‑1370, the af‐fected parameters (S‑0‑0100, S‑0‑0101, P‑0‑1373, P‑0‑1374,P‑0‑1375, P‑0‑1384, P‑0‑1385 and P‑0‑1331) are immediatelyoverwritten with the values of P‑0‑1311. Backup these settingsfirst, if necessary!


Commissioning


Fig. 6-68: Freely selectable set switchingSelection of the parameter set Depending on the application, there are three possibilities of selecting the set

(1 to 4):● Via field bus● Via digital inputs● Via IndraWorks‑Dialog (SYTRONIX 7020 (IMC02)The 4 parameter sets can be selected via P‑0‑1390; bit 14 and bit 15 (pre‐condition: P‑0‑1370; bit 13/12 has been set to 01) via field bus by an externalPLC or via the digital inputs of the IndraDrive. Switching takes place directlywith the selection in P‑0‑1390. The currently active parameter set is fed backin P‑0‑1410 in bits 14 and 15.

P‑0‑1390; bit 15 P‑0‑1390; bit 14 Parameter set

0 0 1

0 1 2

1 0 3

1 1 4

Tab. 6-5: Parameter setIf P‑0‑1390 is configured neither via the digital IndraDrive input nor via the cy‐clic data in the field bus/master communication, the parameter set can alsobe selected manually via the IndraWorks dialog, as follows:1. Select “Freely selectable set switching” (P‑0‑1370; bit 13/12 is automati‐

cally set to 01) as shown in the following figure.

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Fig. 6-69: Selection of the parameter set2. In the “Set selection” field, choose the set to be used (P‑0‑1390; bit

14/15 is automatically set to the corresponding set). The active set isthen replaced by the selected set.

Configuration of the parameter setvalues

The following parameters can be set:

Set 1 Set 2 Set 3 Set 4

Velocity controller proportional gain P‑0‑1311[00] P‑0‑1311[20] P‑0‑1311[40] P‑0‑1311[60]

Integral action time velocity controller P‑0‑1311[01] P‑0‑1311[21] P‑0‑1311[41] P‑0‑1311[61]

P‑factor process controller P‑0‑1311[02] P‑0‑1311[22] P‑0‑1311[42] P‑0‑1311[62]

I‑time process controller P‑0‑1311[03] P‑0‑1311[23] P‑0‑1311[43] P‑0‑1311[63]

D‑factor process controller P‑0‑1311[04] P‑0‑1311[24] P‑0‑1311[44] P‑0‑1311[64]

Filter time pressure increase P‑0‑1311[05] P‑0‑1311[25] P‑0‑1311[45] P‑0‑1311[65]

Filter time pressure drop P‑0‑1311[06] P‑0‑1311[26] P‑0‑1311[46] P‑0‑1311[66]

Lower speed limitation disturbance observer term P‑0‑1311[07] P‑0‑1311[27] P‑0‑1311[47] P‑0‑1311[67]

Tab. 6-6: Parameter settingThe parameter can be changed using the parameter editor for P‑0‑1311 or asfollows via the IndraWorks dialog:1. In the following screen, click Configuration.


Commissioning


Fig. 6-70: Parameter set, configuration2. Select the parameter to be changed in the corresponding set, see the

following figure.3. After changing click “Save parameter sets” (see the following figure); the

parameter takes effect.

Fig. 6-71: Save parameter sets

Master/slave modeUse in applications The master/slave functionality is useful for the following applications:

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Commissioning



● Increase in flow Q by parallel operation of several pumps in the injectionphase or if the required pump size is not available for the requirementsof the application.

● During the pressure holding time to reduce the required motor torquewhich increases the possible pressure holding time.

● During the machine cycle for operation of separate hydraulic circuitswith different pressure.

Coupling type between master/slave

Different types of the master/master/slave configuration;Master mode (configuration by P‑0‑1370; bit 10 = 1)The pressure control is always active.Dynamic master/slave mode (configuration by P‑0‑1370; bit 10 = 0)In the dynamic master/slave mode, the master/slave operation mode can beswitched during operation via the external PLC of the machine (pressure con‐trol only active if switched on via P‑0‑1390; bit 0).Coupling type between master and slave:Analog master/slave subsystem:The value at the pressure control output (= velocity command value) is trans‐mitted to the slaves via an analog signal. Error handling for the subsystemand the valve control are effected via the external PLC of the machine.

Hydraulic setup The hydraulic setup can be● without check valve at the slave pump; all pump outputs are permanent‐

ly interconnected,● effected with check valve at the slave pump so that all pumps work to‐

gether in positive direction if the pressure increases, whereas the pres‐sure drop is only controlled via the master pump.


Commissioning


Fig. 6-72: Master/slave with check valve (1), without check valve (2) and pilotoperated check valve (3)

The user must take the following problems into consideration:1. If the system comprises a check valve it has to be ensured that in case

of performance reduction, the master is not overloaded if all slaves aredeactivated.

2. Without check valve, the system can only be set-up with difficulties asall pumps are directly connected and have to be driven in parallel. If oneslave pump or slave drive fails, the machine control has to switch off thesystem in order to prevent damage to the system due to reversed direc‐tion of rotation.

3. In case of a connection of the slave pump via a pilot operated checkvalve it can be ensured that the slave pump is decoupled as soon as theslave controller is switched off or if an error has been reported.

The following figures show the setup of a master/slave system with field busand analog interface. In the following section, the most important parametersare explained.● Master mode: Pressure control/Q command value mode is active● Slave mode: Q control or velocity control active with special command

value input (see below)

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Fig. 6-73: Master/slave with analog coupling and field bus/master interface

Fig. 6-74: Master/slave with analog coupling and analog master interface


Commissioning


● If no field bus communication is available/activeP‑0‑4089.0.1 = 1 or = 2 or =15), the velocity command valuefor the slave mode is determined via P‑0‑1377 (→ q com‐mand). SVP 7020 IMC then copies the velocity of P‑0‑1377to S‑0‑0036 (velocity command value in velocity mode)

● If field bus communication is available/active, the velocitycommand value for the slave mode is determined viaP‑0‑1282. SVP 7020 IMC then copies the velocity ofP‑0‑1282 to S‑0‑0036 (velocity command value in velocitymode)

● In both cases (with and without active field bus communica‐tion), the velocity command value transferred from the MLDto S‑0‑0036 has a lower limit.→ This minimum velocity is defined with P‑0‑1311[204] in theslave mode. For hydraulic circuits with check valves theparameter must be set to zero!

Configuration of the master/slavemode

The master/slave mode is configured via P‑0‑1370; bit 10:● Bit 10 = 1: Master mode is active

(Pressure control is always on → as soon as the axis is in AF (driveenable); the MLD takes over control and starts pressure control (displayof drive H1 changes to AU). AU indicates that the pressure control is ac‐tive independently of P‑0‑1390; bit 0).

● Bit 10 = 0: Switching between master/slave mode is active.Via P‑0‑1390; bit 0, toggling between master and slave mode is possi‐ble.– "P‑0‑1390, Control word"; bit 0 = 0: Slave mode in Q control– "P‑0‑1390, Control word"; bit 0 = 1: Master mode in p control

● Use P‑0‑1390; bit 0 = 0 to directly set the command speedspecified by the pressure controller in P‑0‑0690 to 0. Thespeed value specified in P‑0‑1282, or P‑0‑1377 becomes ac‐tive immediately.

● If P‑0‑1390; bit 0 = 0, the drive is not in state "AU" and theinternal MLD does not control the drive. The externally se‐lected operation mode is active.

● To execute the slave mode correctly (active commandspeed value via P‑0‑1282 or P‑0‑1377), the drive has to bein the velocity control operation mode.

Automatic internal injection functionUse in applications The functionality reduces pressure overshoots during the injection process by

adjusting the I-term at the actuating variable (speed command value).Principle of operation Only leakage flow/velocity and if required the pressure ratio have to be set.

The operating principle is shown in the following figure:

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Fig. 6-75: Operating principle of injection functionThe overshoots are reduced by internal automatic limitation of the integralcomponent based on the following settings:● The injection function is enabled via (P‑0‑1390 bit 8 = 1).● In P‑0‑1311[210], the ratio of pressure feedback value and pressure

command value is entered at which the limitation of the I-term of thecontroller output starts to be reduced if the injection function has beenactivated (P‑0‑1390; bit 8).

● In P‑0‑1311[211], the ratio of pressure feedback value and pressurecommand value is entered at which an upper limit is set for the I-term ofthe controller output with regard to the leakage velocity (P‑0‑1327).

● In P‑0‑1327, the leakage speed is entered, to which the pump is decel‐erated after the injection function.

● The active limitation of the I-term is displayed in P‑0‑1280.Configuration The configuration can be completed in the following dialog:

Figure "IndraWorks configuration of the injection control" in preparationTips for parameter setting (default

values) Parameter Default value

P‑0‑1311 [209] 0.0000

P‑0‑1311 [210] 0.0000

P‑0‑1311 [211] 0.0000

P‑0‑1327 500

P‑0‑1376 S‑0‑0091

P‑0‑1377 1000.0000

Tab. 6-7: Default values

Leakage compensationUse in applications The leakage compensation serves to guarantee an exact oil flow from the

pump. It compensates, for example, the leakage within the pump so that thecylinders work at a constant speed. Without leakage compensation, a differ‐ence between the command value specified by the external control and theactual oil flow in the system will result due to the pressure-dependent leak‐age.


Commissioning


Fig. 6-76: Leakage compensationPrinciple of operation The principle of operation is as follows:

Fig. 6-77: Leakage compensationThe value calculated for the leakage compensation is added to P‑0‑1377(flow command value of the external control). The compensation value isshown in the figure above by means of the line which shows the workingpoint with the two elements of P‑0‑1311.● Pressure value in bar → P‑0‑1311[209]● Leakage volume in rpm → P‑0‑1311[208]

Configuration The configuration of leakage compensation requires a short setup by the useror the machine control:● Block the cylinder or close the valves● Specify a fixed pressure for the system and start the IMC pressure con‐

trol (pressure holding phase with minimum oil flow)● When the pressure value is reached, enter it in P‑0‑1311[209]● Additionally, enter the corresponding speed of the pump (S‑0‑0040) in

P‑0‑1311[208]

If P‑0‑1311[208] = 0 and P‑0‑1311[209] = 0, leakage compensa‐tion is disabled. In the standard setting of the IMC control, leak‐age compensation is not active.

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Fig. 6-78: Configuration of leakage compensation

Switching the I-term/time constantUse in applications In order to reduce overshooting of the pressure feedback value during dy‐

namic control behavior/fast regulation, the I-term of the pressure controllercan be automatically adjusted, depending on the control difference.

Principle of operation The I-term of the pressure controller can be switched between two values ac‐cording to the difference between the pressure command value and the ac‐tual pressure value:


Commissioning


Fig. 6-79: Switching progress of I-gainConfiguration In element 201 of list parameter P‑0‑1311, enter from which control differ‐

ence P‑0‑1270 the filter time constant active for the pressure controller isswitched over. For the actual switching criterion, a hysteresis of ±2 bar is pro‐vided in the control difference set in P‑0‑1311[201]. As soon as the controldifference S‑0‑1270 (command pressure - feedback pressure) falls below thevalue (P‑0‑1311[201] +2 bar), pressure control is realized with the I-term/filtertime constant specified in P‑0‑1311[200], instead of the previously active filtertime constant of P‑0‑1374 (or of the parameter sets in P‑0‑1311).If the control difference S‑0‑1270 is greater than – (P‑0‑1311[201] - 2 bar),the filter time constant of P‑0‑1374 (or of the parameter sets in P‑0‑1311) be‐comes active again.

1. P‑0‑1311[200] → Tn2 (default value = 5 ms)

2. P‑0‑1374 → Tn1

3. P‑0‑1311[201] → Switching point: (Standard = 10 bar)

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Switching of the filter time constant is always enabled as soon asP‑0‑1311[200] <> 0.Exception: After a negative command value change (P‑0‑1371),switching is NOT active until the feedback value (P‑0‑1273) is forthe first time smaller than the command value (control differencepositive again for the first time). As of this point in time the moni‐toring function for switching is active again.

Notes on commissioning ● Specify a suitable value in P‑0‑1311[201], e.g. “10 bar”● Define a proper value in P‑0‑1311[200], e.g. “5 ms”This value has to be smaller than P‑0‑1374.A typical configuration (default setting) is:P‑0‑1311[201] = 10 barP‑0‑1374 = 20 msP‑0‑1311[200] = 5

Limitation of the disturbance observer (I+D controller output)Use in applications: The upper and the lower limit of the I+D-terms can be used to avoid over‐

shooting or undershooting. The limit is also used for the automatic injectionfunction.

Configuration P‑0‑1331 is the lower limit of the I+D‑actuating variableP‑0‑1376 is the upper limit of the I+D actuating variableNo additional limit of the ID-term at the controller output is set using P‑0‑1331= 0 and P‑0‑1376 = 0. Merely the general controller output limitation is realiz‐ed by P‑0‑1377 and P‑0‑1378. When using P‑0‑1375 = 0 (→ PI-controller),only the I-term is limited by P‑0‑1331 and P‑0‑1376. P‑0‑1278 indicates theID-term (where appropriate, the limited term) specified for the controller out‐put. The currently active upper limit is displayed in P‑0‑1280. Note: While theinjection function is active (P‑0‑1390; bit 8 = 1), it is always the value presetby the injection function that is effective as the upper limit of the ID-term. Thiscan also deviate from the value entered in P‑0‑1376.

Notes on commissioning The default value of parameter P‑0‑1331 has to be set to 0.If the decompression is too slow, the parameter can be set to a negative val‐ue, e.g. -200 rpm.With a very large oil volume, you can even set -1000 rpm for the value. Spe‐cial care is, however, still necessary with large negative values.

6.4.6 Diagnostics including logbookAny present diagnostic messages are displayed as diagnostic code inP‑0‑1300 and as diagnostic text in English in P‑0‑1387. If no diagnostic mes‐sage is present, the text "no event to display" is displayed. Moreover, anywarnings and errors are displayed in the diagnostics of IndraDrive(S‑0‑0095). See also Functional Description: Diagnostics/error handling.Additionally, certain states such as "Pressure control active" and different lim‐it value violations are displayed.The most important diagnostic data are summarized in the overview dialog.The signal light shows three different states of the technology function:● Green: No diagnostics or message● Yellow: Warning● Red: Error


Commissioning


Fig. 6-80: Signal light with states of technology functionThe diagnostic text is displayed in the overview dialog and in the header ofeach detailed dialog.

Fig. 6-81: Diagnostic textThe diagnostic logbook is displayed via the Diagnostic memory button. Thelast 50 diagnostic messages that occurred are recorded in the diagnostic log‐book with their codes (P‑0‑1312[0]...[49]) and time stamps (P‑0‑1312[50]...[99]). The diagnostic messages covered by a diagnostic message of higherpriority in the period of occurrence are also listed here. The respective timestamp represents the operating hours of the control section (P‑0‑0190).

Fig. 6-82: Diagnostic logbookIf required, the diagnostic logbook can be refreshed using the button.

6.5 Configuring the protective functions6.5.1 Introduction and overview

An important part of the software/parameter file of SvP drives is basic protec‐tion from common hazards to the pump and/or the hydraulic system.The following table shows the essential functions in this package:

Features Protection against cavitation Protection against mechani‐cal wear

Improvement of the systemsafety

Pressure command valuelimitation ✓ ✓ ✓

Actual pressure value moni‐toring ✓ ✓ ✓

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Features Protection against cavitation Protection against mechani‐cal wear

Improvement of the systemsafety

Pressure command value/flow limitation ✓ ✓ –

Acceleration limitation ✓ ✓ –

Input power limitation – ✓ –

Cable break monitoring – – ✓

Flexible hose failure detec‐tion – – ✓

Thermal load monitoring – ✓ –

Pressure sensor defect de‐tection ✓ – ✓

Tab. 6-8: Overview of the protective functionsThe protective functions comprise the control input to guarantee the feasibilityof the command values and they limit the control output so that the systemdoes not reach any dangerous operating state. The following figure illustratesthe most important access points of the protective functions.

Red points Access points of the protective functionsFig. 6-83: Access points of the protective functions

Concept With all electrical Rexroth drives, the safety function is integrated into hard‐ware and firmware. Apart from that, the protection of pump and hydraulic sys‐tem is implemented with two components:● a) Requirements and regulations in the official data sheets of the hard‐

ware components (for example suitable oil type for the pump and itsproperties, configuration of the suction line etc.).


Commissioning


● b) Software component which requires that part a) has already beensatisfied. This can be further configured according to the hydraulic sys‐tem to be used so that realistic monitoring required for the application isreached.

These functions only serve the limitation of command values,control of command values and monitoring of actual values (pres‐sure, speed, torque, temperature, etc.). It is not provided that theuser forces additional additive values (for example via S‑0‑0037).

Use in applications The protective functions can be used in SvP systems with open hydraulic cir‐cuits. Only for operation in 1 or 2 quadrants, e.g. internal gear pumps “PGH,PGF, PGM, etc.” and axial piston pumps of series A10xZO for the open cir‐cuit.

● For systems, which are operated in the 4-quadrant mode(e.g. A10VZG) in applications such as compact linear axes,an extension is under planning.

● In configurations with a slave axis, no protective functionsare enabled (see section “Master/slave pump operation”).

For further information, see MPx-020 documentation.

Standard diagnostics ● E2011/12/17 warnings● F2011/12/17 errorsError reaction:With F201x: Execute the best deceleration possible (emergency stop) imme‐diately.

In order to prevent damage to the pump, it has to be checked inevery individual case whether backward rotation of the pump isadmissible before setting of the error reaction to torque disable. Ifnot, mechanical precautions are to be taken in order to prevent it(check valve).

Extended diagnosis Especially for SYTRONIX, various warnings and errors have been definedwhich will be explained in more detail later, see section “List of warnings/errors”.● P‑0‑1300, Error/warning code● P‑0‑1387, Sytronix message text

The direction of rotation causing the pressure increase must al‐ways be positive. Otherwise, operation is not possible and/or thepump may be damaged. Pressure values always refer to the at‐mospheric pressure. This is valid for both, pump data and sensorvalues.If the direction of rotation is not positive, change the weightingsettings/signs of the velocity data.

6.5.2 IndraWorks dialog and areas of protective functionsIn the overview screen of the IMC control function, the following functions areincluded:

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1. Status of the protective functions2. Lower limit of the command values3. User-defined configuration of the protective function4. Selection and/or entry of the pump data

Fig. 6-84: Basic IndraWorks interface of the protective functions

6.5.3 Basic protection settings/default valuesInitialization of the pump data

The software/parameter file waits for information about the connected pump.This information is provided either by selection of one of the types in theIndraWorks dialog or by manual entry of the data.In the overview dialog of basic settings, the pump can be selected in 4. Motorpump component. If the pump type is not contained in the selection list, se‐lect “other pump” and enter the pump data manually, see also "Loading thebasic settings (default values for IMC)" on page 55


Commissioning


Fig. 6-85: Select different pumpEntry of the pump data in the “System configuration” area.

Fig. 6-86: Entry of pump data

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Fig. 6-87: Calling the dialog to enter pump valuesEnter pump data manually, see chapter 8.3 "Data entry pump for IMC " onpage 172.

Fig. 6-88: Manual entry of the pump data

● Apart from the configuration of the pump, the user can havethe current pump data displayed with the dialog above.

● The pump data must be set before the controller is activated(AF, drive enable). As soon as the drive is in the AF condi‐tion, no more changes are taken into consideration. In orderto re-select the pump, return to the AB (drive ready) state.

● If one field of the manually entered data is invalid and if thedrive is switched to AF, error D700 will be generated in orderto prevent the operation. In this case check the feasibility ofthe defined data.

● Elements of the pump data are mapped in list parameterP‑0‑1389, chapter 7 "Parameters and diagnostic messagesfor p/Q control injection molding (IMC)" on page 119.

6.5.4 Pressure limitation and monitoringIn the data sheets of the pump, the following limit values specify the safeoperating range, see highlighting in the next example. In the software/param‐


Commissioning


eter file, this serves the pressure command value limitation and monitoring ofthe actual values:● pmax_critical = P‑0‑1389[175]● pmax_conti = P‑0‑1389[176]● pmin_conti = P‑0‑1389[177]● pmin_critical = 0 bar

Fig. 6-89: Operating range pump pressure

● The protection against inadmissible pressure ranges cannotbe disabled.

● The operation between P‑0‑1389[175] and P‑0‑1389 [176] istemporarily admissible for a maximum period of 10 s.

● The value of P_min_critical = 0 bar as the software/parame‐ter file requires that the pressure at the pump output must begreater than the suction pressure (operation in quadrant 4not taken into account).

● At the pressure sensor, there may be electrical noise whichmay lead to faulty monitoring. That is why pressure monitor‐ing is automatically inactive in a tolerance band defined byP‑0‑1389[149].Example: Electrical output range of the sensor: 0.1: 10 Vand tolerance band = 0.1 V→ Monitoring does not consider the ranges(0.05 to 0.1 V) and (10 to 10.05 V).

Pressure command value limita‐tion

This function comprises basic limitations (for the pump) and additional option‐al user-defined limitations.The command value is limited as follows:● Maximum: P_max_critical (P‑0‑1389[175])● Minimum: P_min_conti (P‑0‑1389[177])

Configuration The user can define new limitations which are admissible if they are withinthe safe operating range.● Pump data, maximum pressure limitations: P‑0‑1389 [175,177] bar.● User-defined limitation of the pressure command value, max.:

P‑0‑1389[101], Standard 0 bar (inactive).

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● User-defined limitation of the pressure command value, min.:P‑0‑1389[102], Standard 5 bar.

P‑0‑1370Bit 22

Enable warning if command value limitation pressure isactive (B203)

0: On (generation of warning is allowed)

1: Off (default, no warning)

● The user-defined limits are ignored if setting = 0 or in case ofincorrect parameterization (P‑0‑1389[101] must be greaterthan P‑0‑1389[102]).

● The following effective pressure command value results:1. Max. command value = min. (P‑0‑1389[101],

P‑0‑1389[175]) if P‑0‑1389[101] > 0, otherwise max.limit = P‑0‑1389[175].

2. Min. command value = max. (P‑0‑1389[102],P‑0‑1389[177]) if P‑0‑1389[102] > 0, otherwise min.command value = P‑0‑1389[177].

Related IndraWorks interface

Fig. 6-90: User-defined activation of the warning with pressure command valuelimitation

Corresponding warnings/errors PLC warning/error E2012 PLC warning no. 2

Code (P‑0‑1300) B203

Text (S‑0‑0095 or P‑0‑1387) Pressure Command Value Limit Active

● Also see P‑0‑1415 and P‑0‑1416 for the reserved messagebits.

● See also P‑0‑1289; Effective max. velocity limitation andP‑0‑1290; Effective min. velocity limitation.

Actual pressure value monitoringBasic This function comprises the thresholds for errors/warnings.

Inadmissible operating ranges:● Pressure ≥ P‑0‑1389[175]● Pressure > P‑0‑1389[176] if operation longer than 10 s● Pressure < 0

● The warnings B201, B202 are generated as notice if pres‐sure > P‑0‑1389[176] or pressure < P‑0‑1389[177].

● The monitoring function does not generate a warning uponsystem start! If actual pressure < P‑0‑1389[177] and speedtoo low ≥ 0, no warning or error is generated.


Commissioning



Code (P‑0‑1300) D101

Text (S‑0‑0095 or P‑0‑1387) Critical Pressure

See "User-defined" on page 104 regarding the warnings B201 and B202.

Also see P‑0‑1415 and P‑0‑1416 for the reserved message bits.

User-defined The pressure monitoring thresholds are mainly defined for the pump, as ex‐plained above. The user may, however, define additional warning thresholdsby means of P‑0‑1389[103][104] which protect other system components.Apart from that, an optional time period T (delay) for the generation of thewarnings may be set.

Fig. 6-91: Debouncing time conceptConfiguration ● Pump data, max. pressure limitations: P‑0‑1389 [175,176,177] bar.

● User-defined upper limit for actual pressure value monitoring:P‑0‑1389[103], Standard 0 (inactive).

● User-defined lower limit for actual pressure value monitoring:P‑0‑1389[104], Standard 0 (inactive).

● Debouncing time T for the generation of warnings of pressure monitor‐ing: P‑0‑1389[105], Standard 0 s (no delay).

● Debounce time T for generating errors of pressure monitoring:P‑0‑1389[106], Standard 0 s (no delay) → from version 02V12.

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● To apply this monitoring function, P‑0‑1389[103] has to be >P‑0‑1389[104].

● Warning B201 is generated if pressure feedback value >P‑0‑1389[103].

● Warning B202 is generated if the pressure feedback value <P‑0‑1389[104].

● If P‑0‑1389[103] = 0, the user-defined threshold is ignored.● If P‑0‑1389[104] = 0, the user-defined threshold is ignored.● Warning B202 will not be generated if the speed command

value = 0 in order to prevent superfluous information in caseof standstill of the axis.

● By default, the debouncing time for error D101 isP‑0‑1389[106] = 0, but the user may increase it at his/herown risk to max. 0.3 [s] → this applies to version 02V12 andabove.


Fig. 6-92: IndraWorks visualization of the active limit valuesCorresponding warnings/errors PLC warning/error E2012 PLC warning no. 2

Code (P‑0‑1300) B201

Text (S‑0‑0095 or P‑0‑1387) High Pressure Level

PLC warning/error E2012 PLC warning no. 2

Code (P‑0‑1300) B202

Text (S‑0‑0095 or P‑0‑1387) Low Pressure Level


6.5.5 Power limitationThe pump capacity is limited to PWmax according to the official data sheet. Inorder to avoid damage, PWmax must not be exceeded. The relevant functioncalculates the corresponding speed limitation internally and applies it to thecontroller output.


Commissioning


Fig. 6-93: Pressure – speed

● This limitation is decisive with high pressure if the maximumflow is required.

● This function cannot be disabled. The user may specify ahigh value for P‑0‑1389[163] (manually defined pump types)in order to avoid the limitation. This can, however, lead todamage.

P‑0‑1370Bit 25

Switch on power limitation

0: On (default)

1: Off

Configuration ● Pump data, max. input power: P‑0‑1389[163] kW.● Debouncing time for warning of the active power limitation:

P‑0‑1389[130], Standard 0 s.● PT1 filter time constant for output limitation: P‑0‑1389[122], Standard

100 ms.Related IndraWorks interface

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Fig. 6-94: IndraWorks visualization of the max. pump power and the actualpower value


Code (P‑0‑1300) B106

Text (S‑0‑0095 or P‑0‑1387) Max Power Limit Active


6.5.6 Speed limitationsTo avoid mechanical wear and possible cavitation in the suction area of thepump, the speed must be limited in negative and positive direction as de‐clared in P‑0‑1389[165].Example: PGH4‑3x/020Limitation N_pos, P‑0‑1389[165] = 3000 rpmLimitation N_neg, -1* P‑0‑1389[165] = -3000 rpmIf a special limitation of the flow command value is required, the limitation in(P‑0‑1377, 78) can be used in the controller structure.

● The negative speed is limited to 0 if the actual pressure val‐ue is lower than P‑0‑1389[177] in order to avoid cavitation.

● This function cannot be disabled. The user may specify ahigh value for P‑0‑1389[165] (manually defined pump types)in order to avoid the limitation. This can, however, lead todamage.

Configuration ● Pump data, max. speed: P‑0‑1389[165] rpm● Debouncing time for warning of the active speed limitation:

P‑0‑1389[128], Standard 0 s.Output Current positive speed limitation*: P‑0‑1296 rpm

P‑0‑1296 shows the minimum value of P‑0‑1389[165] and the cal‐culations of the power limitation.


Code (P‑0‑1300) B104

Text (S‑0‑0095 or P‑0‑1387) Positive Speed Limit Active


Commissioning



Code (P‑0‑1300) B105

Text (S‑0‑0095 or P‑0‑1387) Negative Speed Limit Active



Fig. 6-95: IndraWorks visualization of the max. pump speed

6.5.7 Thermal monitoringIf the pressure is kept constant during operation, the pump can continuouslywork in the stable range shown below.In case of operation at a speed below the ns1 line, there is the risk of heataccumulation if the oil flow which is most important for the heat transmissionis below the thermal steady state. It is thus recommended maintaining aspeed > P‑0‑1389 [166]. In some cases the system leakage is, however, toosmall to satisfy this condition.For the operating fluid HLP46 with an inlet temperature of 50 °C and stand‐ard cleanliness, a special protective function for Rexroth internal gear pumpsis internally implemented in the software/parameter file.The corresponding function is simply a model which monitors the speed asindicator of the thermal stability of the pump in relation to current pressure.The minimum speed ns1 (exchange rate of the liquid) required to avoid heataccumulation and a parameter in % - the “degree of heat” specifying the ther‐mal stability - are output.If the degree of heat exceeds 90 % warning B109 is generated in order to in‐dicate overheating. If it reaches 9 8%, error D100 is generated and the oper‐ation is stopped as otherwise, mechanical wear may result.

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Fig. 6-96: Pump operating ranges referred to thermal stabilityIn the following cases, heat accumulation is insignificant:● Low pressure level (pressure <= P_therm)● Negative speed

Configuration ● Pump data, min. positive speed: P‑0‑1389[166] rpm● Debouncing time for the generation of warning B108: P‑0‑1389[131],

Standard 0.1 s.● Reduction factor cooling time: P‑0‑1389[124], Standard 3.


Commissioning


● The diagram described above only applies to integrated in‐ternal gear pumps by Rexroth, series PGH.

● The factor of 1→3 in P‑0‑1389[124] is a measure for the heatdissipation of the pump (in a thermally stable state). Factor 1describes a pump, which cools down slowly (e.g. at high am‐bient temperature), factor 3 (default) a pump, which coolsdown faster (e.g. at room temperature). A higher “cooling-down coefficient" therefore means faster cooling down of thepump and thus a shorter recovery time between two high-pressure cycles.

● In case of continuous operation at a speed below the ns6line, the speed/displacement is not sufficient to compensatefor internal pump leakage. Consequently, the pump cannotmaintain the system pressure, which results in a slow pres‐sure reduction in the system. Warning B108 informs aboutthat situation.

● In case of operation at a speed of almost zero, the unwanted“stick-slip effect” may occur due to the motor torque and themechanical friction in the pump at the beginning of themovement. This leads to very high pressure pulses and - inthe course of time - to mechanical defects. Therefore, thepump should not be stopped (speed = 0) in the normal cycle.

P‑0‑1370Bit 23

Enable model-based thermal stability monitoring

0: On (default)

1: Off

P‑0‑1370Bit 18

Action if 98 % of the degree of heat is exceeded

0: Error (default)

1: Warning (deactivation of error D100)

Output Minimum safe positive speed (ns1), rpm: P‑0‑1297Current degree of heat, %: P‑0‑1298


Fig. 6-97: User-defined activation of monitoring for thermal overloadCorresponding warnings/errors PLC warning/error F2011 PLC error no. 1

Code (P‑0‑1300) D100

Text (S‑0‑0095 or P‑0‑1387) Excessive Heat Accumulation

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Code (P‑0‑1300) B108

Text (S‑0‑0095 or P‑0‑1387) Low Positive Speed


Code (P‑0‑1300) B109

Text (S‑0‑0095 or P‑0‑1387) Danger of Heat Accumulation


6.5.8 Limitation of the flow command valueThe limitation refers to the entry of the flow command value as shown in thefigure below.The upper limit, P‑0‑1389[110] called “Soft start limit” is only taken into con‐sideration during system start and is active if the two conditions are met:

1. The pressure is lower than the defined minimum pressure commandvalue Pcommand_min.Pcommand_min is calculated as follows:→ Pcommand_min = max. (P‑0‑1389[102], P‑0‑1389 [177]).If P‑0‑1389[102] > 0, otherwise Pcommand_min = P‑0‑1389[177].

2. Speed command value, P‑0‑0048 = 0 for duration ≥ 100 ms

Fig. 6-98: Influence of the limitation on the flow command valueConfiguration Upper limit flow command value, soft start: P‑0‑1389 [110], Standard 500 rpm

Lower limit flow command value: P‑0‑1389[111], Standard 40 rpm

P‑0‑1370Bit 19

Enable warning if flow command value limitation is active

0: On (generation of warning is allowed)

1: Off (default, no warning)


Commissioning


● If P‑0‑1389[110] = 0, the soft start threshold is disabled.● With a wrong configuration, if P‑0‑1389 [110] <

P‑0‑1389[111] but P‑0‑1389[110] > 0, the entire limitation isdisabled.

● From the application’s point of view, the limitation inP‑0‑1389 [111] usually is used to compensate continuousleakage.


Fig. 6-99: User-defined activation of monitoring of the flow command value lim‐itation


Code (P‑0‑1300) B204

Text (S‑0‑0095 or P‑0‑1387) Flow rate Command Value Limit Active


6.5.9 Acceleration limitationsThe upper limits are primarily defined by entering the pump data,P‑0‑1389[168]. Apart from that, the user may define new limitations with theparameters P‑0‑1329 and P‑0‑1330 (see controller structure documentation).

● If P‑0‑1389[168] = 0, the primary limitation is disabled.

The acceleration may be limited optionally, depending on the current pres‐sure (pressure-dependent acceleration limitation).

Configuration ● Pump data, max. bipolar acceleration: P‑0‑1389 [168] rad/s²● Debouncing time for the generation of waring B107: P‑0‑1389[131],

Standard 0 s● Total of the load moments of inertia regarding the pump axis, JL:

P‑0‑1389[123] gm2, Standard 0.

P‑0‑1370Bit 17

Enable pressure-dependent acceleration limitations

0: On

1: Off (standard)

Output Current acceleration limitation: P‑0‑1299 rad/sec²

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Commissioning




Fig. 6-100: IndraWorks visualization of the current acceleration limitation

Fig. 6-101: User-defined activation of monitoring of the pressure-dependent ac‐celeration limitation


Code (P‑0‑1300) B107

Text (S‑0‑0095 or P‑0‑1387) Acceleration Limit Active


6.5.10 Detection of pipe damageThis optional function detects excessive leakage which may have beencaused by a sudden pipe damage in the hydraulic system.If the requirements below are met, the following error is generated upon de‐tection:

1. Pressure is lower than a predefined threshold, P*2. Speed is higher than a predefined threshold, N*3. Condition 1 and 2 last longer than a defined period T*

Configuration Pressure threshold pipe damage detection, P*: P‑0‑1389 [143], Standard 2barSpeed threshold pipe damage detection, N*: P‑0‑1389 [144], Standard 1000rpmDebouncing time of error D201, T*: P‑0‑1389[151], Standard 1 s

● If P* or N* <= 0, this monitoring function will be internally dis‐abled.

● Monitoring is automatically inactive upon system start (seethe soft start conditions in section “Flow command value lim‐itation”) in order to avoid the generation of superfluous er‐rors.

P‑0‑1370Bit 20

Enable pipe defect monitoring

0: On (default)

1: Off


Commissioning



Fig. 6-102: User-defined activation of tube failures monitoring

6.5.11 Pressure sensor monitoringThe plausibility of the pressure sensor signal is monitored by two detectionfunctions:● Pressure sensor cable break detection (activated via P‑0‑1370; bit 28)● Detection of faults of the sensor signal - pressure sensor detect detec‐

tion (activation via P-0-1370, bit 21)

● It is assumed that the pressure sensor is connected to theanalog input type 1 of the drive controller.

● If pressure sensors with current output are used, firmwaremonitoring F2270 has to be activated via P‑0‑0255. Themonitoring function described here will then be inactive.

The following example explains how a suitable scaling for the assignment ofanalog input A is estimated if none of the predefined sensor types has beenselected.Example:A sensor outputting 0 to 400 bar and scaled in the range from 0.1 to 10 V isto be configured as follows:● P‑0‑0214 (scaling at 10 V) = 400 bar● P‑0‑0215 (scaling at 0 V) = - (400/9.9) = - 4.04 bar● P‑0‑0216 (dead zone) = 0

Fig. 6-103: Pressure sensor operating range and scaling

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Commissioning



Configuration ● Analog input, assignment A, full scaling at 10 V: P‑0‑0214 bar● Analog input, assignment A, signal value at 0V: P‑0‑0215 barThe following control bits have the states ON/OFF

P‑0‑1370Bit 21

Activate pressure sensor defect detection

0: On (default)

1: Off

P‑0‑1370Bit 28

Activate pressure sensor cable break detection

0: On (default)

1: Off


Fig. 6-104: User-defined activation of pressure sensor monitoring functionsPressure sensor cable break de‐

tectionDuring the detection, the input signal range in P‑0‑0210 is checked and anerror is generated if the signal value is not within the expected range and tol‐erance zone (electrical noise is to be taken into consideration).

Fig. 6-105: Pressure sensor operating range with tolerance limitsConfiguration Amplitude of pressure signal: P‑0‑1389[149], Standard 0.1 V

Corresponding warnings/errors PLC warning/error F2012 PLC error no. 2

Code (P‑0‑1300) D203

Text (S‑0‑0095 or P‑0‑1387) Pressure Sensor Data Out of Range


A defined time span of 200 ms is internally set as debouncingtime for the error generation.


Commissioning


Detection of faults of the pressuresensor signal - pressure sensor

defect detection

As a faulty sensor signal may also occur within the expected measuringrange, another examination will then be carried out at positive and negativespeed.

Pressure sensor defect detectionat positive speed

This function comprises an observer comparing the actual value of the motortorque S‑0‑0084 to all calculated possible loads (pressure, acceleration, los‐ses).The losses usually amount to approx. 10-15 % of S‑0‑0084. A large or nega‐tive deviation is an indication of unrealistic signal data. The monitoring func‐tion for pressure sensor defects uses 2 configurable thresholds(P‑0‑1389[140] and [141]) to calculate the losses.

Configuration ● Check sensor signal, torque losses, error threshold: P‑0‑1389[140],Standard 0 [%]

● Check sensor signal, torque losses, warning threshold: P‑0‑1389[141],Standard 15[%].

● Total of the load moments of inertia regarding the pump axis, JL:P‑0‑1389[123] gm2, Standard 0.


Code (P‑0‑1300) D205

Text (S‑0‑0095 or P‑0‑1387) Faulty Sensor Signal


Code (P‑0‑1300) B205

Text (S‑0‑0095 or P‑0‑1387) Pressure Sensor Signal Relative Low


● A defined time span of 200 ms is internally set as debounc‐ing time for error D205.

● If P‑0‑1389[140] = 0, the error threshold is not taken intoconsideration.

● If P‑0‑1389[141] = 0, the error threshold is not taken intoconsideration.

Pressure sensor defect detectionat negative speed

This function checks the changes in the pressure signal at negative rotation.It uses the volume taken from the system and generates an error if no or onlya small pressure drop (< 10 %) is detected although 10 % of the system vol‐ume in P‑0‑1389[142] has been removed.

Configuration Max. oil volume of hydraulic system: P‑0‑1389[142], Standard 50 [L].Related IndraWorks interface

Fig. 6-106: Configuration of the detection of the max. oil volume at negativespeed.

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Commissioning




Code (P‑0‑1300) D202

Text (S‑0‑0095 or P‑0‑1387) Pressure Sensor Data Frozen

See also P‑0‑1415 and P‑0‑1416 for the reserved message bits.

● To calculate the flow, the function refers to the displacementof the pump in P‑0‑1389[160].

● If the user sets P‑0‑1389 [142] = 0, this module is disabled!


Commissioning


7 Parameters and diagnostic messages for p/Q controlinjection molding (IMC)

7.1 Relevant parametersRelevant parameters

Parameters and page in parameter description

chapter 7.3 "P-0-1271, Active pressure command value" on page 120

chapter 7.4 "P-0-1275, Pump displacement - effective" on page 121

chapter 7.5 "P-0-1276, IMC controller cycle time" on page 122

chapter 7.6 "P-0-1278, Disturbance observer term, limited" on page 122

chapter 7.7 "P-0-1280, Upper limit of disturbance observer, effective" on page 122

chapter 7.8 "P-0-1281, Swivel angle feedback value" on page 123

chapter 7.9 "P-0-1282, Speed command value in slave operation (master communication)" on page 123

chapter 7.10 "P-0-1285, Effective flow command value" on page 124

chapter 7.11 "P-0-1289, Effective max. velocity limitation " on page 125

chapter 7.12 "P-0-1290, Effective min. velocity limitation" on page 125

chapter 7.13 "P-0-1295, Lower safe velocity limit" on page 125

chapter 7.14 "P-0-1296, Max. safe positive speed limitation" on page 126

chapter 7.15 "P-0-1297, Min. safe positive speed limitation" on page 126

chapter 7.16 "P-0-1298, Actual degree of heat" on page 127

chapter 7.17 "P-0-1299, Safe acceleration limitation" on page 127

chapter 7.18 "P-0-1300, Error/warning code" on page 127

chapter 7.19 "P-0-1301, Flow feedback value" on page 128

chapter 7.20 "P-0-1311[0 ... 70] parameter set memory (4 sets)" on page 128

chapter 7.21 "P-0-1311[200]], I - integral action time 2" on page 130

chapter 7.22 "P-0-1311[201], Filter time constant 2 switching threshold" on page 132

chapter 7.23 "P-0-1311[204], Minimum speed in slave operation" on page 134

chapter 7.24 "P-0-1311[208], Leakage compensation, determination speed" on page 134

chapter 7.25 "P-0-1311[209], Leakage compensation, determination pressure" on page 135

chapter 7.26 "P-0-1311[210], Injection: Pressure ratio, beginning of ramp, inject. phase speed limit" on page 136

chapter 7.27 "P-0-1311[211], Injection: Pressure ratio, end of ramp, injection phase speed limit" on page 137

chapter 7.28 "P-0-1312[0 ... 99], Error/warning history" on page 137

chapter 7.29 "P-0-1318, Cam, switch-on threshold" on page 138

chapter 7.30 "P-0-1319, Cam, switch-off threshold" on page 139

chapter 7.31 "P-0-1320, P-gain – set 2" on page 140

chapter 7.32 "P-0-1321, I-integral action time, set 2" on page 140

chapter 7.33 "P-0-1322, ParaSet: Switch point, set 2" on page 141


Parameters and diagnostic messages for p/Q control injection molding (IMC)


Parameters and page in parameter description

chapter 7.34 "P-0-1323, ParaSet: Switch point, set 1" on page 141

chapter 7.35 "P-0-1324, Injection: Smoothing time constant" on page 142

chapter 7.36 "P-0-1326, Factor of speed switching threshold for cam " on page 142

chapter 7.37 "P-0-1327, Injection: Final speed, injection function" on page 143

chapter 7.38 "P-0-1329, Acceleration limitation of pump speed" on page 144

chapter 7.39 "P-0-1330, Deceleration limitation of pump speed" on page 144

chapter 7.40 "P-0-1331, IMC control: Lower limitation of disturbance observer" on page 145

chapter 7.41 "P-0-1370, Configuration" on page 145

chapter 7.42 "P-0-1373, IMC control: P-gain" on page 148

chapter 7.43 "P-0-1374, I-integral action time" on page 148

chapter 7.44 "P-0-1375, IMC control: D-component/disturbance observer factor" on page 149

chapter 7.45 "P-0-1376, Upper limitation of disturbance observer" on page 150

chapter 7.46 "P-0-1377, Flow command value" on page 150

chapter 7.47 "P-0-1378, Controller output limitation, negative" on page 151

chapter 7.48 "P-0-1383, Lower limitation of D component" on page 152

chapter 7.49 "P-0-1384, PT1 command value filter, filter time constant, ascent" on page 152

chapter 7.50 "P-0-1385, PT1 command value filter, filter time constant, descent" on page 153

chapter 7.51 "P-0-1387, Sytronix message text" on page 153

chapter 7.52 "P-0-1389, [100 ... 200] Protective function parameters" on page 154

chapter 7.53 "P-0-1390, Control word" on page 156

chapter 7.54 "P-0-1410, Status word" on page 157

chapter 7.55 "P-0-1411, Cam status word" on page 158

chapter 7.56 "P-0-1415, SF warnings" on page 159

chapter 7.57 "P-0-1416, SF error messages" on page 160

chapter 7.58 "S-0-0800, Pressure command value" on page 160

chapter 7.59 "S-0-0813, System pressure" on page 161

chapter 7.60 "S-0-0827, Pressure control deviation" on page 161

chapter 7.61 "S-0-0832, Pressure window" on page 162

Tab. 7-1: Pertinent parameters

For further information, see MPx-20 documentation.

7.2 Parameter description

7.3 P-0-1271, Active pressure command valueP‑0‑1271 displays the actually effective command value at the controller inputthat is used to generate the control deviation.The value can be filtered (PT1 command value filter P‑0‑1384 or P‑0‑1385).

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Min./max. value -/-

Format DEC_MV

Unit bar

Type Output register

Editable --

Decimal places 4

Buffered parameter No

Default value -

Refresh time P‑0‑1276

Tab. 7-2: Parameter attributesSee chapter 7.1 "Relevant parameters" on page 119.

7.4 P-0-1275, Pump displacement - effectiveP‑0‑1275 displays the effective displacement of the pump(s).The following cases have to be considered:● Double pump with Vg1 and Vg2● Variable displacement pump with 2-point behavior with VG_min and

VG_max● Variable displacement pump with variable displacement (0…100 %)To display a correct value, the pump volume has to be correctly entered inP‑0‑1389[160].If the volume of a further pump (VG2) has been entered in P‑0‑1389[161],this volume is additionally taken into account in P‑0‑1275 and P‑0‑1301 (de‐pending on P‑0‑1411; bit 0).For variable displacement pumps (e.g. A10), the maximum displacement hasto be specified in P‑0‑1389[160]. The minimum displacement has to be speci‐fied in P‑0‑1389[161].Displacements to be specified:● Vgmin the minimum displacement V2 of P‑0‑1389.161 (in case of double

pump systems, this corresponds to the displacement of the first pump).● Vgmax the maximum displacement (in case of double pump systems, this

corresponds to the displacement of both pumps V1+V2 of P‑0‑1389.160+ P‑0‑1389.161, or, in case of 2-point control, V1 of P‑0‑1389.160).

Min./max. value 0.0/-P-0-1378

Format DEC_OV

Unit ccm


Editable --

Decimal places 1





Default value -

Refresh time 200 ms


7.5 P-0-1276, IMC controller cycle timeP‑0‑1276 displays the cycle time of the pressure controller in the drive. Thecycle time depends on the control section hardware, or on the device designand the device load.

Min./max. value 1/-

Format DEC_OV

Unit µs


Editable --

Decimal places 0


Default value -

Refresh time 200 ms


7.6 P-0-1278, Disturbance observer term, limitedP-0-1278, Disturbance observer

term, limitedThe disturbance observer term (ID-term) is displayed in the IMC controller(the disturbance observer term can be limited) in P‑0‑1278. The limitation isrealized by P‑0‑1331 and P‑0‑1376.

Min./max. value -/-

Format DEC_MV

Unit rpm


Editable --

Decimal places 4


Default value -

Refresh time 200 ms


7.7 P-0-1280, Upper limit of disturbance observer, effectiveP‑0‑1280 displays the effective upper limit for the disturbance observer term(ID-term). This value is usually derived from P‑0‑1376. If the injection phase

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has been activated via P‑0‑1390, the limit can be set to another value (cf. in‐jection function).

Min./max. value -/-

Format DEC_MV

Unit rpm


Editable --

Decimal places 4


Default value -

Refresh time 200 ms


7.8 P-0-1281, Swivel angle feedback valueP‑0‑1281 displays the sensor signal of the swivel angle feedback value of thevariable displacement pump. The value can be read in using the externalsensor via an analog input.

This value is used to calculate the effective displacement(P‑0‑1275). It is set to 100 % if VG is constant.

Min./max. value -/-

Format DEC_MV

Unit %

Type Input register

Editable ++

Decimal places 4


Default value -

Refresh time P-0-1276


7.9 P-0-1282, Speed command value in slave operation (mastercommunication)

During slave mode of master/slave switching, the speed command value forthe slave drive is provided by P‑0‑1282.If necessary, the effective value is limited downward by P‑0‑1311[204].




Input via P‑0‑1282 is only possible with an active field bus mastercommunication (P‑0‑4089.0.1 ≥ 3 and <> 15). Otherwise, the val‐ue from P‑0‑1377 is used for the speed command value input inslave operation.For correct slave operation, the velocity control mode has to beactive in the drive (speed input by internally writing S‑0‑0036).

Min./max. value -/-

Format DEC_MV

Unit rpm

Type Input register

Editable ++

Decimal places 4


Default value -



7.10 P-0-1285, Effective flow command valueThis parameter displays the effective flow command value Q_cmd (after leak‐age compensation and the integrated protective function).

Fig. 7-1: Defining the effective flow command value

Min./max. value -/-

Format DEC_OV

Unit rpm


Editable --

Decimal places 2


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Default value -

Refresh time P‑0‑1276


7.11 P-0-1289, Effective max. velocity limitation The parameter displays the effective max. velocity limit as a result of protec‐tive function and pressure controller. This value takes effect as the controlleroutput limitation.

Min./max. value -/-

Format DEC_MV

Unit rpm


Editable --

Decimal places 2


Default value -

Refresh time 200 ms


7.12 P-0-1290, Effective min. velocity limitationThe parameter displays the effective min. velocity limit as a result of protec‐tive function and pressure controller. This value takes effect as the controlleroutput limitation.

Min./max. value -/-

Format DEC_MV

Unit rpm


Editable --

Decimal places 2


Default value -

Refresh time 200 ms


7.13 P-0-1295, Lower safe velocity limitThe parameter displays the current lower velocity limit for information. Thisvalue takes effect as the controller output limitation.




Min./max. value -/-

Format DEC_MV

Unit rpm


Editable --

Decimal places 2


Default value -

Refresh time 200 ms


7.14 P-0-1296, Max. safe positive speed limitationThe parameter displays the current maximum positive limitation. This value isused to limit the controller output.

Min./max. value -/-

Format DEC_OV

Unit rpm


Editable --

Decimal places 2


Default value -



7.15 P-0-1297, Min. safe positive speed limitationThe parameter displays the current minimum positive limitation. This value isused to avoid overheating in case of low speed.

Min./max. value -/-

Format DEC_OV

Unit rpm


Editable --

Decimal places 2


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Default value -



7.16 P-0-1298, Actual degree of heatThis parameter shows the estimated temperature load on the basis of thecurrent load and operation at a speed below ns1.

Min./max. value -/-

Format DEC_OV

Unit %


Editable --

Decimal places 4


Default value -

Refresh time 200 ms


7.17 P-0-1299, Safe acceleration limitationThe parameter contains the limit values for acceleration.

Min./max. value -/-

Format DEC_MV

Unit rad/s2


Editable --

Decimal places 2


Default value -



7.18 P-0-1300, Error/warning codeThe parameter displays the last error/warning code.

Min./max. value -/-

Format HEX




Unit -


Editable --

Decimal places 0


Default value -

Refresh time 200 ms


7.19 P-0-1301, Flow feedback valueIn P‑0‑1301, the actual flow displaced by the pump is displayed (P‑0‑1301 =P‑0‑1275 * S‑0‑0040). To display a correct value, the displacement of thepump has to be correctly input in P‑0‑1389 [160]. If the volume of a furtherpump has been entered in P‑0‑1389[161], this volume is additionally taken in‐to account in P‑0‑1301 (depending on P‑0‑1411; bit 0).

Min./max. value -/-

Format DEC_MV

Unit ccm/min


Editable --

Decimal places 1


Default value 0



7.20 P-0-1311[0 ... 70] parameter set memory (4 sets)In list parameter P‑0‑1311, those parameter contents are stored in the ele‐ments [0] to [70] to which it is possible to switch with P‑0‑1390; bit 14/15 inthe case of external parameter set switching (P‑0‑1370; bit 13/12 = 0/1).Structure of list parameter P‑0‑1311 and significance of the list elements:

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Element Meaning Unit Set number

0 Set1: S‑0‑0100 Nm/(rad/s)

Set I

1 Set1: S‑0‑0101 ms

2 Set1: P-gain (P‑0‑1373) rpm/bar

3 Set1: I-integral action time (P‑0‑1374) ms

4 Set1: D-gain (P‑0‑1375) rpm/(bar/s)

5 Set1: Command value filter, ascent (P‑0‑1384) ms

6 Set1: Command value filter, descent (P‑0‑1385) ms

7 Set1: Limitation of controller output, lower (P‑0‑1331) rpm

8 to 19

20 Set2: S‑0‑0100 Nm/(rad/s)

Set II

21 Set2: S‑0‑0101 ms







28 to 39

40 Set3: S‑0‑0100 Nm/(rad/s)

Set III

41 Set3: S‑0‑0101 ms







48 to 59

60 Set4: S‑0‑0100 Nm/(rad/s)

Set IV

61 Set4: S‑0‑0101 ms







Tab. 7-19: Structure of list parameter P‑0‑1311 and significance of the list ele‐ments




Min./max. value -/-

Format DEC_OV

Unit -

Type Input register

Editable ++

Decimal places 4

Buffered parameter Yes

Default value 0



7.21 P-0-1311[200]], I - integral action time 2In list parameter P‑0‑1311[200], the filter time constant for the I-term of thecontroller is entered which takes effect when the filter time constant is switch‐ed. Thus, overshooting in the control behavior in the case of a positive com‐mand value jump can be reduced by the changed filter time constant for the I-term.

At a certain control deviation defined in P‑0‑1311[201], the inte‐gral time constant that takes effect for the I-term in the pressurecontroller is switched.

If the control deviation S‑0‑0827 (command pressure - feedback pressure)falls below (P‑0‑1311[201] + 2 bar), pressure control is realized with the I-term/integral time constant specified in P‑0‑1311[200], instead of the previ‐ously effective integral time constant from P‑0‑1374 (or from the parametersets in P‑0‑1311).If the control deviation S‑0‑0827 is greater than (–1)*(P‑0‑1311[201] - 2 bar),the I-integral action time of P‑0‑1374 (or of the parameter sets in P‑0‑1311)takes effect again.

Switching of the I-integral action time is always active as soon asP‑0‑1311[200] <> 0.Exception: After a negative command value change, switching isNOT active until the feedback value is for the first time smallerthan the command value (control deviation positive again for thefirst time). From this point, the monitoring function for switching isactive again.

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① P‑0‑1374, or of parameter set 1 - 4 is active② P‑0‑1311[200] activeFig. 7-2: Parameterizing the I-integral action time

Min./max. value 0/-

Format DEC_OV

Unit ms

Type Input register

Editable ++

Decimal places 0


Default value 0

Refresh time 200 ms





7.22 P-0-1311[201], Filter time constant 2 switching thresholdList parameter P‑0‑1311[201] specifies from which control deviation S‑0‑0827the filter time constant active for the pressure controller for the integral term isswitched in the IMC controller. For the actual switching criterion, a hysteresisof +/- 2 bar is provided in the control deviation set in P‑0‑1311[201]. As soonas the control deviation S‑0‑0827 (command pressure - feedback pressure)falls below the value - (P‑0‑1311[201] + 2 bar), pressure control is realizedwith the I-term/integral time constant specified in P‑0‑1311[200], instead ofthe previously active integral time constant of P‑0‑1374 (or of the parametersets in P‑0‑1311). If the control deviation S‑0‑0827 is greater than -(P‑0‑1311[201] - 2 bar), the filter time constant of P‑0‑1374 (or of the parame‐ter sets in P‑0‑1311) is active again.

Switching of the I-integral action time is always active as soon asP‑0‑1311[200] <> 0.Exception: After a negative command value change, switching isNOT active until the feedback value is for the first time smallerthan the command value (control deviation positive again for thefirst time). From this point, the monitoring function for switching isactive again.

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① P‑0‑1374, or of parameter set 1 - 4 is active② P‑0‑1311[200] activeFig. 7-3: Parameterizing the switching threshold for the second filter time con‐

stant

Min./max. value 0/-

Format DEC_OV

Unit bar

Type Input register

Editable ++

Decimal places 0


Default value 0

Refresh time 200 ms





7.23 P-0-1311[204], Minimum speed in slave operationIn slave operation (input of flow command value Q_cmd), the value ofP‑0‑1282 or P‑0‑1377 (depending on the master communication in the drive)is used for providing the velocity command value S‑0‑0036. If the value en‐tered in P‑0‑1282/P‑0‑1377 is smaller than the value entered inP‑0‑1311[204], the value of P‑0‑1311[204] is specified in S‑0‑0036.

For correct slave operation, the velocity control mode has to beactive in the drive.Slave operation is active if P‑0‑1370; bit 10 = 0 and P‑0‑1390; Bit0 = 0.

See also “Master/slave operation”

Min./max. value -/-

Format DEC_MV

Unit rpm

Type Input register

Editable ++

Decimal places 4


Default value 0.0000

Refresh time 200 ms


7.24 P-0-1311[208], Leakage compensation, determination speed

Fig. 7-4: Determining the additive speed command value for leakage compen‐sation for a specific pressure

The additive speed command value for leakage compensation is defined bythe intersection of P2 (pressure) and Q2 (oil flow) in the above figure.In list parameter P‑0‑1311[208], the speed feedback value is entered whichwas identified with the pressure feedback value when the leakage had beendetermined.

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If P‑0‑1311[208] = 0 and P‑0‑1311[209], no leakage compensa‐tion takes place! Consequently, the additive speed command val‐ue is always 0.

Also see chapter "Leakage compensation" on page 91

Min./max. value -/-

Format DEC_MV

Unit rpm

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.25 P-0-1311[209], Leakage compensation, determination pres‐sure

Fig. 7-5: Parameterization for a specific reference pressure for leakage com‐pensation

The additive speed command value for leakage compensation is defined bythe above characteristic curve and determined by the vertex p2/Q2 (see fig‐ure). In list parameter P‑0‑1311[209], the pressure feedback value is enteredat which the leakage velocity had been determined. Also see chapter "Leak‐age compensation" on page 91

If P‑0‑1311[208] = 0 and P‑0‑1311[209], no leakage compensa‐tion takes place! Consequently, the additive speed command val‐ue is always 0.

Min./max. value -/-

Format DEC_MV




Unit bar

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.26 P-0-1311[210], Injection: Pressure ratio, beginning of ramp,inject. phase speed limit

Fig. 7-6: Working principle of injection control – feedforward velocityIn P‑0‑1311[210], the ratio of pressure feedback value and pressure com‐mand value is entered at which the limitation of the I-term of the controlleroutput starts to be reduced with active injection function (P‑0‑1390; bit 8).The active limit of the I-term is displayed in P‑0‑1280.

If a value <= 0.0000 % is entered in P‑0‑1311[210], the value43.0000 % takes effect as the pressure ratio for the start of theramp

Min./max. value 0.0000/100.0000

Format DEC_OV

Unit %

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms

Tab. 7-26: Parameter attributes

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See chapter 7.1 "Relevant parameters" on page 119.

7.27 P-0-1311[211], Injection: Pressure ratio, end of ramp, injec‐tion phase speed limit

Fig. 7-7: Working principle of injection control – feedforward velocityIn P‑0‑1311[211], the ratio of pressure feedback value and pressure com‐mand value is entered at which the I-term of the controller output is limited tothe leakage speed (P‑0‑1327) with active injection function (P‑0‑1390; bit 8).The active limit of the I-term is displayed in P‑0‑1280.

If a value <= 0.0000 % is entered in P‑0‑1311[211], the value70.0000 % takes effect as the pressure ratio for the end of theramp.

Min./max. value 0.0000/100.0000

Format DEC_OV

Unit %

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.28 P-0-1312[0 ... 99], Error/warning historyThis parameter stores up to 50 error/warning messages generated by the Sy‐tronix protective function, along with the time stamp based on the operatinghours of the control section. The first 50 elements contain the error/warningcode, the next 50 elements contain the corresponding time.

Min./max. value -/-

Format DEC_OV




Unit -


Editable --

Decimal places 0

Buffered parameter Yes, at phase change AB -> BB

Default value -

Refresh time 200 ms


The recorded points in time are actually the elapsed operatinghours of the control section (P‑0‑0190), rounded to the nearesttwo-digit integer.


7.29 P-0-1318, Cam, switch-on thresholdIn conjunction with the two-point control or double pump operation, a dis‐placement change function with definable thresholds is used. It can be con‐figured using the following parameters:● P‑0‑1318, Cam, switch-on threshold● P‑0‑1319, Cam, switch-off threshold● P‑0‑1411, Cam status word

Fig. 7-8: Switching progression and threshold for changing the pump dis‐placement

If the pressure feedback value S‑0‑0813 or the pressure difference (ΙS‑0‑0827 Ι) (selection with P‑0‑1370; bit 11) exceeds the value entered inP‑0‑1318, bit 0 is set in P‑0‑1411, Cam status word. If P‑0‑1318 andP‑0‑1319 are 0 at the same time, the cam is disabled, i.e. bit 0 in P‑0‑1411 isalways 0.If the value in P‑0‑1318, cam, switch-on threshold is smaller than the value inP‑0‑1319, cam, switch-off threshold, it is indicated in the status wordP‑0‑1410 in bit 11.

138/183




Min./max. value 0,000/-

Format DEC_MV

Unit bar

Type Input register

Editable ++

Decimal places 3


Default value 0.000

Refresh time 200 ms


7.30 P-0-1319, Cam, switch-off thresholdIn conjunction with the two-point control or double pump operation, a dis‐placement change function with definable thresholds is used. It can be con‐figured using the following parameters:● P‑0‑1318, Cam, switch-on threshold● P‑0‑1319, Cam, switch-off threshold● P‑0‑1411, Cam status word

Fig. 7-9: Switching progression and threshold for changing the pump dis‐placement

Switching can take place independently of the system pressure or the pres‐sure differential.

Changeover in dependence onsystem pressure

If the actual pressure value S‑0‑0813 falls below the switch-off thresholdP‑0‑1319, cam P‑0‑1411 Bit 0 deactivates.

Changeover in dependence onpressure differential

If the control deviation S‑0‑0827 falls below the switch-off threshold P-0-1319and motor speed S‑0‑0040 below the configured speed threshold (dependingon P‑0‑1326), cam P‑0‑1411 bit 0 is deactivated.





Format DEC_MV

Unit bar

Type Input register

Editable ++

Decimal places 3


Default value 0.000

Refresh time 200 ms


7.31 P-0-1320, P-gain – set 2Besides parameter set switching with up to 4 sets that can be externally con‐trolled, the integrated automatic parameter set switching is provided for theIMC controller and can be used for IMC with double pump/variable displace‐ment pump to adjust the IMC controller gain to the active displacement of thepump.Parameter P‑0‑1320 is used to preset the second P-gain for the pressurecontroller for automatic switching of the controller setting (P‑0‑1370; Bit 13=1). If switching of the controller setting has not been set with P‑0‑1322/P‑0‑1323, P‑0‑1320 does not have any function.

Min./max. value 0.0000/-

Format DEC_OV

Unit rpm/bar

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.32 P-0-1321, I-integral action time, set 2Besides parameter set switching with up to 4 sets that can be externally con‐trolled, the integrated automatic parameter set switching is provided for theIMC controller and can be used for IMC with double pump/variable displace‐ment pump to adjust the IMC controller gain to the active displacement of thepump.Parameter P‑0‑1321 is used to preset the second I-integral time of the pres‐sure controller for automatic switching of the controller setting (P‑0‑1370; bit

140/183




13 =1). If switching of the controller setting has not been set with P‑0‑1322/P‑0‑1323, P‑0‑1321 does not have any function.


Format DEC_OV

Unit ms

Type Input register

Editable ++

Decimal places 3



Refresh time 200 ms


7.33 P-0-1322, ParaSet: Switch point, set 2Apart from remote parameter set switching with up to 4 sets, integrated auto‐matic parameter set switching is provided for the IMC controller depending onthe pressure feedback value S‑0‑0813 (can be selected using P‑0‑1370; bit13/12 = 1/0). This can be used for IMC with double pump/variable displace‐ment pump to adjust the IMC controller gain to the active displacement of thepump.If automatic set switching depending on the pressure feedback value is set inP‑0‑1370 (P‑0‑1370; bit 13/12 = 10) and if the absolute value of the pressurefeedback value (P‑0‑0813) exceeds the value entered in P‑0‑1322, other val‐ues are valid for P-gain and I-integral action time of the PID-controller(P‑0‑1320/P‑0‑1321). If P‑0‑1323 = 0 and P‑0‑1322 = 0, the controller set‐tings are not switched. The active controller setting is displayed in P‑0‑1410;bit 12.


Format DEC_OV

Unit -

Type Input register

Editable ++

Decimal places 4


Default value 0.000

Refresh time 200 ms


7.34 P-0-1323, ParaSet: Switch point, set 1Apart from remote parameter set switching with up to 4 sets, integrated auto‐matic parameter set switching is provided for the IMC controller depending on




the pressure feedback value S‑0‑0813 (can be selected using P‑0‑1370; bit13/12 = 1/0). This can be used for IMC with double pump/variable displace‐ment pump to adjust the IMC controller gain to the active displacement of thepump.If automatic set switching depending on the pressure feedback value is set(P‑0‑1370; bit 13/12 = 10) in P‑0‑1370 and if the pressure feedback value(P‑0‑0813) falls below the value entered in P‑0‑1323, the original values arevalid for P-gain and I-integral action time of the PID-controller (P‑0‑1373/P‑0‑1374). If P‑0‑1323 = 0 and P‑0‑1322 = 0, the controller settings are notswitched. The active controller setting is displayed in P‑0‑1410; bit 12.


Format DEC_OV

Unit -

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.35 P-0-1324, Injection: Smoothing time constantIn parameter P‑0‑1324, the filter time constant of the PT1 filter is preset forfiltering the pressure ratio. The filtered pressure ratio is used to calculate thelimitation of the I-term during the injection phase (P‑0‑1390; bit 8 = 1).

Min./max. value 0/-

Format DEC_OV

Unit ms

Type Input register

Editable ++

Decimal places 0


Default value 20

Refresh time 200 ms


7.36 P-0-1326, Factor of speed switching threshold for cam Factor for calculating the switching speed for double pump operation/2-pointdisplacement, according to the formulanswitching threshold = factor from P‑0‑1326 * nmax * VGmin/VGmax

142/183




If the actual speed is smaller than this value and, at the same time, the con‐troller deviation (pressure command value - pressure feedback value) issmaller than the value set in P‑0‑1319, the smaller displacement is set (in thecase of double pumps, the second pump is disconnected and in the case of apump with 2-point control, the pump is swiveled back).

2-point control/double pump switching is carried out only if thishas been configured accordingly in P‑0‑1370; bit 9/8.

Min./max. value 0.5/0.9

Format DEC_OV

Unit -

Type Input register

Editable ++

Decimal places 1


Default value 0.9

Refresh time 200 ms


7.37 P-0-1327, Injection: Final speed, injection function

Fig. 7-10: Working principle of injection control – feedforward velocityThe leakage speed is entered in parameter P‑0‑1327. This value is requiredfor the injection function (cf. P‑0‑1390; bit 8): As soon as the ratio of pressurefeedback value and pressure command value has reached the value fromP‑0‑1311[211], the DI-term of the controller output (speed) is limited (upward)to this value. The active limitation of the DI-term is displayed in P‑0‑1280.

Min./max. value 0/-

Format DEC_OV

Unit rpm

Type Input register

Editable ++




Decimal places 0


Default value 500

Refresh time 200 ms


7.38 P-0-1329, Acceleration limitation of pump speedUse P‑0‑1329 to specify the maximum possible pump acceleration. If the cal‐culated controller output is increased by more than the specified value, the in‐crease in the controller output (command acceleration) is limited to the speci‐fied value. The controller output, the ascent of which may be limited, is dis‐played in P‑0‑1274.

If P‑0‑1329 = 0, no additional acceleration and deceleration limitis set. If P‑0‑1329 <>0 and P‑0‑1330 = 0, a deceleration limit isstill set. As value of the deceleration limit, the value of P‑0‑1329 isused in this case.


Format DEC_OV

Unit rad/s2

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.39 P-0-1330, Deceleration limitation of pump speedUse P‑0‑1330 to specify the maximum possible pump deceleration. If the cal‐culated controller output is decreased by more than the specified value, thedecrease of the controller output (command acceleration) is limited to thespecified value. The controller output, the descent of which may be limited, isdisplayed in P‑0‑1274.

If P‑0‑1329 = 0, no additional acceleration and deceleration limitis set. If P‑0‑1329 <>0 and P‑0‑1330 = 0, a deceleration limit isstill set. As value of the deceleration limit, the value of P‑0‑1329 isused in this case.


Format DEC_OV

144/183




Unit rad/s2

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.40 P-0-1331, IMC control: Lower limitation of disturbance ob‐server

Via P‑0‑1331, the controller output term of the disturbance observer can belimited downward. P‑0‑1278 indicates the term (if required, the limited term)of the disturbance observer specified for the controller output. The upper limitof the disturbance observer term is entered in P‑0‑1376.The lower limit always uses the value from P‑0‑1331. If no lower limit is re‐quired, a great value has to be entered with correct polarity in P‑0‑1331(P‑0‑1331 < P‑0‑1378).In case of external parameter set switching (P‑0‑1370; bit 13/12 = 0/1), thevalid value of P‑0‑1311 of the parameter set selected using P‑0‑1390 is dis‐played in P‑0‑1331.

Min./max. value -/-

Format DEC_MV

Unit rpm

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.41 P-0-1370, ConfigurationBit Designation/function Comment

1/0 Controller output, i.e. controller output signal00: Velocity command value

Set with regard to which variable in the drive the proc‐ess controller takes effect.

2 Reserved

4/3 Pressure feedback value source00: Analog input/external sensor (S‑0‑0813)

Sets the origin of the pressure feedback value.




5 Switch-off behavior0: Controller output = 0

Sets the drive behavior during pressure controllerswitch off.

6 Not used

7 Digital output, cam status word0: Not inverted1: Inverted

Using this bit, it is possible to invert the bit for chang‐ing the displacement P‑0‑1411, bit 0, if necessary,e.g. to control a variable displacement pump or doublepump with inverted logic.

8 Activating the “2-point control / double pump” function1: Deactivated0: Activated

It is possible to specifically deactivate the changingdisplacement function (default = 0!).

9 System configuration0: 2-point control1: Double pump

With this bit, the maximum and minimum displace‐ments are calculated by means of the user input.

10 Activating dynamic master/slave operation0: Dynamic master/slave operationMaster/slave switching possible via P‑0‑1390, bit 0:1: Master operation as soon as drive in “AF”; pressurecontrol incl. monitoring functions always active

This bit is used to select the operation mode for theuse of several axes. If bit 10 = 1, the system is themaster axis and always in pressure control. It providesthe speed for the slave axes. If bit 10 = 0, the systemcan operate in pressure control, depending on thestate of parameter P‑0‑1390 bit 0 = TRUE (see chap‐ter 7.53 "P-0-1390, Control word" on page 156), andestablish its own actuating variable for speed like amaster or, if bit it 0 = FALSE, operate in pure speedcontrol like a slave with the speed being provided by amaster.

11 Type of double pump switching0: Switching depending on pressure feedback valueS‑0‑08131: Switching depending on control deviation S‑0‑0827

This bit selects which signal is crucial for double pumpswitching.

13/12 Controller parameter switching00: None01: Controlled set mode (4 sets)10: Automatic, depending on pressure feedback valueS‑0‑081311: Automatic, depending on power requirements (de‐pending on P‑0‑1411; bit 0, i.e. pressure differenceand S‑0‑0040)

01: Controlled direct set selection via P‑0‑1390; bit15/14.1x: Automatic controller switchover depending onS‑0‑0813, or P‑0‑1411; bit 0.Bit 12: This bit defines the source of the switching sig‐nal which can be S‑0‑0813 or P‑0‑1411; bit 0.10: Effective switching points: P‑0‑1322 andP‑0‑1323.11: Effective switching points: P‑0‑1318 and P‑0‑1319as well as the value in S‑0‑0040.Note: With “11“ selected, the corresponding switchingcondition still has to be configured –> see change ofdisplacement for double pump operation!

14 Continuous swivel angle adjustment:0: No variable displacement pump connected or varia‐ble displacement pump in 2-point operation1: Operation of a variable displacement pump withcontinuous swivel angle adjustment

Using this bit, set whether the swivel angle feedbackvalue (P‑0‑1281) is used for calculating the effectivedisplacement (P‑0‑1301).

16/15 Not assigned

146/183




17 Enable pressure-dependent acceleration limitations0: On1: Off (standard)

Part of the protective function, see chapter 6.5 "Con‐figuring the protective functions" on page 96.

18 Active if 98 % of degree of heat is exceeded0: Error (default)1: Warning (disable error D100)


19 Enable warning if flow command value limitation is ac‐tive0: On (generation of warning is allowed)1: Off (default, no warning)


20 Enable pipe defect monitoring0: On (default)1: Off


21 Activate pressure sensor defect detection0: On (default)1: Off

Part of the protective function, see chapter 6.5 "Con‐figuring the protective functions" on page 96.Change of function as of version 02V14

22 Enable warning if pressure command value limitationactive0: On (generation of warning is allowed)1: Off (default, no warning)


23 Enable the model-based thermal stability monitoring0: On (default)1: Off


24 Allow notices by warning E20170: On (default)1: Off


25 Switch on power limitation0: On (default)1: Off


26 ... 27 Not assigned

28 Activate pressure sensor cable break detection0: On (default)1: Off

Part of the protective function, see chapter 6.5 "Con‐figuring the protective functions" on page 96.As of version 02V14

29 Basic setting loaded1: Starting value for initial commissioning0: Marker for recommissioning after first run

IndraWorks writes and evaluates this bit to display thecorrect dialogs; it does not have any functional signifi‐cance.

30 Master communication selection:0: Analog1: Field bus

IndraWorks writes and evaluates this bit to display thecorrect dialogs; it does not have any functional signifi‐cance.

31 Not assigned

Tab. 7-41: Parameter structure




Min./max. value 0/-

Format BIN

Unit -

Type Input register

Editable ++

Decimal places 0


Default value -

Refresh time 200 ms


7.42 P-0-1373, IMC control: P-gainParameter P‑0‑1373 is used to specify the P-gain of the pressure controller.

In case of external parameter set switching (P‑0‑1370; bit 13/12 =0/1), the valid value of P‑0‑1373 of the parameter set selected us‐ing P‑0‑1390 is displayed in P‑0‑1311.


Format DEC_OV

Unit rpm/bar

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.43 P-0-1374, I-integral action timeParameter P‑0‑1374 is used to specify the integral action time (I-term) of thepressure controller. If this integral action time is smaller than or equal to thecontroller cycle time (e.g., 2 ms, see P‑0‑1276), the I-term internally used forthe controller output calculation is set to zero and thus does not have any ef‐fect. The I-integral action time (P‑0‑1374) only takes effect for the typical PI-controller (P‑0‑1375, Disturbance observer factor = 0). If the value inP‑0‑1375, Disturbance observer factor, is unequal to zero, the time entered inP‑0‑1374 takes effect as the filter time constant of the PT1 filter in the disturb‐ance observer.

148/183




In case of external parameter set switching (P‑0‑1370; bit 13/12 =0/1), the valid value of P‑0‑1311 of the parameter set selected viaP‑0‑1390 is displayed in P‑0‑1374.

Min./max. value 0/-

Format DEC_OV

Unit ms

Type Input register

Editable ++

Decimal places 0


Default value 10

Refresh time 200 ms


7.44 P-0-1375, IMC control: D-component/disturbance observerfactor

Via parameter P‑0‑1375, the basic controller structure of the IMC controllercan be changed.P‑0‑1375 = 0 is a PI-controllerP‑0‑1375 ≠ 0 is a P-controller with disturbance observer.Use the value in P‑0‑1375 to set how the disturbance observer influences thepressure control.



Format DEC_OV

Unit rpm/(bar/s)

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms





7.45 P-0-1376, Upper limitation of disturbance observerVia P‑0‑1376, the controller output term of the disturbance observer can belimited upward. P‑0‑1278 indicates the term (if required, the limited term) ofthe disturbance observer specified for the controller output. The lower limit ofthe disturbance observer term is entered in P‑0‑1331. If the value in P‑0‑1376= 0, the value of P‑0‑1377 constitutes the upper limit. In case of an active in‐jection function (P‑0‑1390; bit 8 = 1), the value preset by the injection functionis always active as the upper limit of the ID-term. This value can differ fromthe value entered in P‑0‑1376, if the ratio of pressure feedback value andpressure command value exceeds the value of P‑0‑1311[210]. As long asP‑0‑1376 = 0 and the ratio of pressure feedback value and pressure com‐mand value is smaller than the value entered in P‑0‑1311[210], the ID-term ofthe controller output is limited upward to the value entered in P‑0‑1376.If P‑0‑1376 = 0, P‑0‑1377 is active even in case of an active injection function(as long as the ratio of pressure feedback value and pressure command val‐ue is smaller than the value entered in P‑0‑1311[210]). See also the descrip‐tion of P‑0‑1377. The currently active upper limit is displayed in P‑0‑1280.

Min./max. value -/-

Format DEC_MV

Unit rpm

Type Input register

Editable ++

Decimal places 4


Default value S-0-0091

Refresh time 200 ms


7.46 P-0-1377, Flow command valueWith P‑0‑1377, the flow command value is transmitted to the p/Q controller in[rpm], in which it is used within the framework of a minimum value compara‐tor.P‑0‑1377 constitutes the upper velocity limit of the pressure controller output.The status word P‑0‑1410; bit 2 displays whether the limitation is active.● As long as P‑0‑1376 = 0, the value of P‑0‑1377 is also used for the low‐

er limitation of the disturbance observer term (see also description ofP‑0‑1376).

● The value entered in P‑0‑1377 is also used for the injection function(P‑0‑1390; bit 8 = 1)

● As long as P‑0‑1376 = 0 and the ratio of pressure feedback value andpressure command value is smaller than the value entered inP‑0‑1311[210], the ID-term of the controller output is limited upward tothe value entered in P‑0‑1377.

● With active slave operation / Q command value control (→ P‑0‑1370; bit10 = 0 and P‑0‑1390; bit 0 = 0) and no active master communication

150/183




(P‑0‑4089.0.1 <= 2 or = 15), the value of P‑0‑1377 is internally preset tothe drive as S‑0‑0036, Velocity command value.

● The entered value has to have the correct polarity.

Besides P‑0‑1377 , all other velocity limit values in the drive haveto be taken into account which might limit the controller output(e.g., S‑0‑0091). The speed limit from S‑0‑0091 (default value =1000 rpm) always takes effect. If necessary, the value inS‑0‑0091 has to be adjusted!● In the dynamic master / slave operation, the velocity control

mode has to be active in the drive (speed input by internallywriting S‑0‑0036).

● If during master/slave operation (without active master com‐munication!), the value entered in P‑0‑1377 is smaller thanthe value entered in P‑0‑1311[204], the value ofP‑0‑1311[204] is specified in S‑0‑0036.

● The actually effective value for limiting the controller outputcan furthermore be reduced by the protective functions or in‐creased by active leakage compensation. For this purpose,the effective speed command value P‑0‑0690 at the pres‐sure controller output has to be considered.

Min./max. value -/-

Format DEC

Unit rpm

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


7.47 P-0-1378, Controller output limitation, negativeUsing this parameter, it is possible to set a lower limit for the process control‐ler output. The status word P‑0‑1410; bit 3 displays whether the limitation isactive.

In order not to limit the controller output, enter accordingly highnegative values in P‑0‑1378 (e.g., P‑0‑1378 < -S‑0‑0091). Theentered value has to have the correct polarity. The speed limitfrom S‑0‑0091 (default value = 1000 rpm) always takes effect. Ifnecessary, the value in S‑0‑0091 has to be adjusted!

Min./max. value -/-

Format DEC




Unit rpm

Type Input register

Editable ++

Decimal places 4


Default value -1000.0000

Refresh time 200 ms


7.48 P-0-1383, Lower limitation of D componentParameter P‑0‑1383 sets a downward limit for the D-term of the disturbanceobserver.

There only is a downward limitation, but no upward limitation. Theentered value must be signed.

Min./max. value -/-

Format DEC_OV

Unit rpm

Type Input register

Editable ++

Decimal places 4


Default value -200.0000 rpm

Refresh time 200 ms


7.49 P-0-1384, PT1 command value filter, filter time constant, as‐cent

Enter the filter time constant for the ascent of the command value filter in pa‐rameter P‑0‑1384. The filtered command value is displayed in P‑0‑1271. WithP‑0‑1384 = 0, the command value filter (ascent) is deactivated, and P‑0‑1271corresponds to the unfiltered, possibly inverted command value S‑0‑0800. Ifthe parameterized filter time constant is smaller than or equal to the cycletime of the pressure controller P‑0‑1276, the command value filter is deacti‐vated and does not have an effect on the command value.


152/183




Min./max. value 0/-

Format DEC_OV

Unit ms

Type Input register

Editable ++

Decimal places 0


Default value 0

Refresh time 200 ms


7.50 P-0-1385, PT1 command value filter, filter time constant, de‐scent

Enter the filter time constant for the descent of the command value filter inparameter P‑0‑1385. The filtered command value is displayed in P‑0‑1271.With P‑0‑1385 = 0, the command value filter (descent) is deactivated, andP‑0‑1271 corresponds to the unfiltered command value S‑0‑0800. If the para‐meterized filter time constant is smaller than or equal to the cycle time of thepressure controller P‑0‑1276, the command value filter is deactivated anddoes not have an effect on the command value.


Min./max. value 0/-

Format DEC_OV

Unit ms

Type Input register

Editable ++

Decimal places 0


Default value 0

Refresh time 200 ms


7.51 P-0-1387, Sytronix message textThe parameter P‑0‑1387 is used to display the message texts of the monitor‐ing and protective functions.




Min./max. value -/-

Format ASCII

Unit -


Editable --

Decimal places 0


Default value -

Refresh time 200 ms


7.52 P-0-1389, [100 ... 200] Protective function parametersThe table below provides an overview of all elements used. This documenta‐tion contains further details on the contents of the modules. The format of allelements is = “signed decimal with 3 decimal places“, and the data length is 4bytes.

Element no. Range Standard I/O Use

100 ≥ 0 40 I Pump type (default: PGH4-3X/20)

101 ≥ 0 0 I User-defined pressure command value limitation, max., bar

102 ≥ 0 5 I User-defined pressure command value limitation, min., bar

103 ≥ 0 0 I User-defined upper pressure monitoring limit, bar

104 ≥ 0 0 I User-defined lower pressure monitoring limit, bar

105 ≥ 0 0 I Debounce time to generate pressure monitoring warnings,s

106 0 ≤ Value≤ 0.3 0 I

Debounce time for the error of the pressure monitoringD101As of version 02V12

110 ≥ 0 500 I Flow command value limitation, soft start, rpm

111 ≥ 0 40 I Flow command value limitation, min., rpm

112 ... 121 Reserved

122 ≥ 0 100 I PT1 filter time constant for output power limits, ms

123 ≥ 0 0 I Load inertia with respect to pump axis, gm2

124 ≥ 0 3 I Cooling time reduction factor for thermal monitoring


128 ≥ 0 0 I Debounce time for active speed limit warning, s

129 ≥ 0 0 I Debounce time for active acceleration limit warning, s

130 ≥ 0 0 I Debounce time for active power limit warning, s

131 ≥ 0 0.1 I Debounce time to generate the warning B108, s

154/183




Element no. Range Standard I/O Use


140 ≥ 0 0 I Sensor signal check, torque losses, error threshold %

141 ≥ 0 15 I Sensor signal check, torque losses, warning threshold %

142 > 0 50 I Max. hydraulic system oil volume, l

143 > 0 2 I Pipe defect detection pressure threshold, bar

144 > 0 1000 I Pipe defect detection speed threshold, rpm

145, 148 Reserved

149 > 0 0.1 I Sensor noise amplitude, V

150 Reserved

151 ≥ 0 1 I Debounce time for pipe defect detection error [s]


160 > 0 20.1 I/O Vg1, cm³ (displacement)

161 > 0 20.1 I/O Vg2, cm³ for variable displacement pumps

162 > 0 - I/O Reserved

163 > 0 35 I/O Max. input power, kW

164 > 0 0.37 I/O Pump inertia with regard to rotor axis, gm2

165 > 0 3000 I/O Max. allowed bipolar continuous speed, rpm

166 > 0 300 I/O Min. allowed positive continuous speed, rpm

167 Reserved

168 > 0 0 I/O Max. bipolar acceleration, rad/s²


175 > 0 350 I/O Max. critical pressure, bar

176 > 0 315 I/O Max. allowed continuous pressure, bar

177 > 0 3 I/O Min. allowed continuous pressure, bar


Tab. 7-53: Protective function parameters

Min./max. value -/-

Format DEC_MV

Unit -


Editable --

Decimal places 3


Default value -

Refresh time 200 ms






7.53 P-0-1390, Control wordThe parameter P‑0‑1390 is used as the (cyclic) control word of process con‐trol.

Bit Designation/function Comment

0 Master/slave operation0: Slave operation (external speed control)1: Master operation (p/Q control)

Activate/enable process control or master/slaveswitching; only takes effect if P‑0‑1370; bit 10 = 0 (de‐fault setting).

1 Freeze controller output (speed command value) Freeze controller output.

2 Control of digital output If pressure control has been deactivated using bit 0(see above), this bit can be freely written and, whereapplicable, assigned to a digital output.

3-5 Reserved

6 Load IMC default values0 → 1 edge

The parameters of the IMC function are set to defaultvalues.

7 Reserved

8 Adaptive injection function0: Not active1: Active

Input to pressure controller that injection process isactive.

9 Reserved

10 Error reset of monitoring functions Bit 10 is used for the protective function to reset theerror state, if required.

11 ... 13 Reserved

14/15 Parameter set switching:00: Activate set 101: Activate set 210: Activate set 311: Activate set 4

These bits can be used to switch the pressure control‐ler parameterization, if this has been configured inP‑0‑1370; bit 13/12 (P‑0‑1370; bit 13/12 = 0/1).See chapter parameter set switching.


Min./max. value -/-

Format BIN

Unit -

Type Input register

Editable ++

Decimal places 0


Default value -



156/183





7.54 P-0-1410, Status wordThe parameter P‑0‑1410 is used as status word of process control.


0 Control active Control was activated with “Enable” (P‑0‑1390; bit 0)and initialization has been completed.

1 Pressure command value reached0: Pressure difference > tolerance window (S‑0‑0832)1: Pressure difference > tolerance window (S‑0‑0832)

Indication if pressure control deviation (S‑0‑0800 andS‑0‑0813) is within the tolerance window (S‑0‑0832).

2 Upper speed limit active Controller output (speed) is limited by P‑0‑1377.

3 Lower speed limit active Controller output (speed) is limited by P‑0‑1378.

4 Warning of IMC software reported Collective bit of all Sytronix software warnings.

5 Controller configuration error Configuration error in the pressure controller reported,e.g. P‑0‑1377 < P‑0‑1378.

6 Enabling of functional packages of Sytronix missing0: SYX functional package is selected1: SYX functional package is not selected

Error bit if P‑0‑2003; bit 7 (SYX functional package) isnot set.

7 Master/slave operation0: Master operation (p/Q control)1: Slave operation (external speed control)

8 Injection process0: Not active, i.e. no additional limitation of the permit‐ted observer filter term P‑0‑12801: Active and additional limitation of the allowed ob‐server filter term P‑0‑1280

This bit signals whether the allowed observer filterterm P‑0‑1280 is limited during the injection process(P‑0‑1390; bit 8 =1).

9 Switching I-integral action time (pressure controller)0: Standard I-integral action time P‑0‑1374 or parame‐ter sets in P‑0‑1311 become active.1: I-integral action time of P‑0‑1311[200] becomes ac‐tive

10 Drive enable0: Enable set (in control)1: Enable not set

The drive is not in drive enable during activation ofprocess control

11 Changing displacement status1: Switch-on threshold (P‑0‑1318) < Switch-off thresh‐old (P‑0‑1319)0: Switch-on threshold (P‑0‑1318) ≥ Switch-off thresh‐old (P‑0‑1319)

Function status displacement change: Switch-onthreshold (P‑0‑1318) is smaller than switch-off thresh‐old (P‑0‑1319).

12 Active controller setting0: Controller setting 1 is active (P‑0‑1373, P‑0‑1374)1: Controller setting 2 is active (P‑0‑1320, P‑0‑1321)

It is displayed which controller settings are currentlyactive (see chapter “automatic controller switching”).




13 Error of IMC software reported Collective bit of all Sytronix software errors.

14/15 Active parameter set00: Set 1 active01: Set 2 active10: Set 3 active11: Set 4 active

If external parameter set switching has been config‐ured (P‑0‑1370; bit 13/12 = 0/1), the active parameterset selected by P‑0‑1390; bit 14/15 is displayed here.


Min./max. value -/-

Format BIN

Unit -


Editable --

Decimal places 0


Default value -



7.55 P-0-1411, Cam status wordParameter P‑0‑1411 is used as status word of the generated cams. When thegeneration of a cam or bit has been activated via the configuration, the re‐spective bit in P‑0‑1411 is written depending on the configuration.


0 Cam, double pump switching0: Switch-on value not reached or value has fallen be‐low switch-off value (and sporadically actual speedbelow the specified switching threshold)1: Value has exceeded switch-on value or not yet fall‐en below switch-off value

The bit is generated depending on the switchingthresholds P‑0‑1318 and P‑0‑1319 (hysteresis func‐tion). Depending on the setting in P‑0‑1370; bit 11, ei‐ther the pressure feedback value S‑0‑0813 or the con‐trol deviation S‑0‑0827 is used together with the ac‐tual speed S‑0‑0040.

1 - 15 Reserved


Min./max. value 0/-

Format BIN

Unit -


Editable --

Decimal places 0


158/183




Default value -



7.56 P-0-1415, SF warningsBit Significance (SF warning 1)) Comment

0 Pressure sensor signal relatively low (B205:Pressure Sen‐sor Signal Relatively Low)

1-2 Not used

3 Excessive heat accumulation (D100:Excessive Heat Accu‐mulation)

4 Pressure command value limitation active (B203:PressureCommand Value Limit Active)

5 High pressure level (B201:High Pressure Level)

6 Low pressure level (B202:Low Pressure Level)

7 Flow command value limitation activated (B204:Flow RateCommand Value Limit Active)

8 Positive speed limitation active (B104:Positive Speed LimitActive)

9 Negative speed limitation active (B105:Negative SpeedLimit Active)

10 Power limitation active (B106:Max Power Limit Active)

11 Acceleration limitation active (B107:Acceleration Limit Ac‐tive)

12 Low positive speed (B108:Low Positive Speed)

13 Overtemperature (B109:Danger of Heat Accumulation)

14-15 Not used

1) SF = safety and protective functionsTab. 7-61: Warnings

Min./max. value -/-

Format DEC_OV

Unit -


Editable --

Decimal places 0


Default value -

Refresh time 1 ms






7.57 P-0-1416, SF error messagesBit Significance (SF error messages 1)) Comment

0 Critical pressure level (D101:Critical Pressure)

1 Scaling error of velocity/torque polarity (D702:Vel.\TorquePolarity Scaling Error)

2-9 Not used

10 Incorrect sensor data (D205:Faulty Sensor Signal)

11 Detection of excessive leakage (D201:Tube Failure Detec‐ted)

12 Pressure sensor data out of allowed range (D203:Pres‐sure Sensor Data Out of Range)

13 Pressure sensor data frozen (D202:Pressure Sensor DataFrozen)

14 Error of pump/system data (D700:Pump/Sys Data Error)

15 Internal SF error (D701:Internal SF Error) Due to in‐correct cal‐culations

1) SF = safety and protective functionsTab. 7-63: Error messages

Min./max. value -/-

Format DEC_OV

Unit -


Editable --

Decimal places 0


Default value -

Refresh time 1 ms


7.58 S-0-0800, Pressure command valueUse S‑0‑0800 to specify the command value for the pressure controller (IMCcontroller). The command value can be preset by a control via the mastercommunication (field bus or analog input).

Min./max. value -/-

Format DEC_MV

Unit bar

Type Input register

160/183




Editable ++

Decimal places 4


Default value -



7.59 S-0-0813, System pressureUse S‑0‑0813 to read the actual value for the pressure controller (IMC con‐troller). This parameter is normally assigned to the analog input of the drive.Scaling and filtering take place before the transmission to S‑0‑0813.

Min./max. value -/-

Format DEC_MV

Unit bar

Type Input register

Editable ++

Decimal places 4


Default value -



7.60 S-0-0827, Pressure control deviationIn S‑0‑0827, the pressure difference actually effective for the PID pressurecontroller is displayed. The pressure feedback value S‑0‑0813 is deductedfrom the pressure command value S‑0‑0800. The value is used to generate"Done" (P‑0‑1410; bit 1).

Min./max. value -/-

Format DEC_MV

Unit bar


Editable --

Decimal places 4


Default value -

Refresh time 200 ms





7.61 S-0-0832, Pressure windowThe pressure tolerance S‑0‑0832 defines a range around the preset pressurecommand value (S‑0‑0800). When the pressure feedback value (S‑0‑0800) iswithin this range, the pressure controller returns “Done” in the status word(P‑0‑1410; bit 1), i.e. the active control deviation (S‑0‑0827) is smaller thanthe pressure tolerance defined in S‑0‑0832.


Format DEC_MV

Unit bar

Type Input register

Editable ++

Decimal places 4



Refresh time 200 ms


162/183




7.62 Error and warning messages for injection molding control(IMC)

Each error message and warning has a unique diagnostic message, e.g.B109 (see table below).

● Error messages start with the letter D.● Warnings start with the letter B.

S-0-0390Error/warning

S-0-0095Text

P-0-1300Code (16 bit hex)

P-0-1387Description

Pump error messages

F2011 D100: Excessive heat accumulation D100 Excessive heat accumulation 1)

F2011 D101: Critical pressure D101 Critical pressure 1)

Pump warnings

E2011 B104: Positive speed limit active B104 Positive speed limit active

E2011 B105: Negative speed limit active B105 Negative speed limit active

E2011 B106: Power limitation active B106 Power limitation active

E2011 B107: Acceleration limitation active B107 Acceleration limit active

E2011 B108: Low positive speed B108 Low positive speed

E2011 B109: Overtemperature B109 Overtemperature

Hydraulics error messages

F2012 D201: Pipe defect detected D201 Pipe defect detected 1)

F2012 D202: Pressure sensor data frozen D202 Pressure sensor data frozen 1)

F2012 D203: Pressure sensor data out of al‐lowed range

D203 Pressure sensor data out of allowedrange 1)

F2012 D205: Faulty sensor signal D205 Faulty sensor signal 1)

Hydraulics warnings

E2012 B201: High pressure level B201 High pressure level

E2012 B202: Low pressure level B202 Low pressure level

E2012 B203: Pressure command value limit ac‐tive

B203 Pressure command value limit activa‐ted

E2012 B204: Flow command value limit active B204 Flow command value limit activated

E2012 B205: Pressure sensor signal relativelylow

B205 Pressure sensor signal relatively low

E2013-16F2013-16

Reserved

Internal MLD error messages

F2017 D700: Pump/system data error D700 Pump/system data error 1)

F2017 D701: Internal error, SF modules D701 Internal error, SF modules 1) 2)




S-0-0390Error/warning

S-0-0095Text

P-0-1300Code (16 bit hex)

P-0-1387Description

F2017 D702: Velocity/torque polarity scalingerror

D702 Velocity/torque polarity scaling error 1)

F2017 D703: No SYX functional package D703 No SYX functional package 1)

Additional messages

E2017 3) B7xx: PLC warning no. 7 B7xx Miscellaneous additional tips

1) This output value is shown only briefly as flag in parameterP‑0‑1387. For monitoring of state, see diagnostic messageS‑0‑0095.

2) SF = safety and protective functions3) If bit 24 in configuration word P‑0‑1370 = 1, warning E2017 is

disabledTab. 7-69: List of warnings/error messages

7.63 Troubleshooting guideCode(P‑0‑1300)

Error descriptionS‑0‑0095(P‑0‑1387 edge)

Cause Remedy

D100 Excessive heataccumulation

Very high thermal load due to longoperation at low speed and highpressure.

● Tolerate higher flow rate (speed greater than on‐line value in P‑0‑1297), before the value of thedegree of heat (P‑0‑1298) reaches 98 %.

● The error is disabled if P‑0‑1370, bit 18 = 0.Thermal load monitoring is disabled if P‑0‑1370,bit 23 = 1.

D101 Critical pressure

Very high pressure level >P_max_criticalor pressure too low (< P_min_criti‐cal)

● Check the hydraulic system.● Check specified pump data with regard to selec‐

ted type P‑0‑1389[170 → 174].

D201 Pipe defect de‐tected

Excessive leakage detected, i.e.Speed > P‑0‑1389[144][rpm] andPressure < P‑0‑1389[143] [bar]for a duration of more thanP‑0‑1389[151] [s]

● Check hydraulic system components.● Setting the thresholds = 0 disables the monitor‐

ing function, as well as the setting P‑0‑1370; bit20 = 1.

D202 Pressure sensordata frozen

Motor runs in negative direction fora long time without considerable re‐duction in P_act signal.(10-% thresholds of P‑0‑1389[142][L] elapsed, with the pressure [bar]not falling by 10 %)

● Check whether cable/sensor is defective.● Check input values in P‑0‑1389[142] on the ba‐

sis of system volume.● This monitoring function can be deactivated if

P‑0‑1389[142] = 0 (a hazardous state can devel‐op).

D203Pressure sensordata out of al‐lowed range

Value of the analog input (pressuresensor output) out of expectedrange.

● Check whether sensor cable is defective.● Check configurations and tolerance of analog in‐

put in P‑0‑1389[149].● This monitoring is disabled if P‑0‑1370, bit 21 =

1.

164/183




Code(P‑0‑1300)

Error descriptionS‑0‑0095(P‑0‑1387 edge)

Cause Remedy

D205 Faulty sensorsignal

The value of the analog input (pres‐sure sensor output) is faulty with re‐gard to the measured torque.

● Check whether cable/sensor is defective.● Check input values in P‑0‑1389[140].● This monitoring is disabled if P‑0‑1370, bit 21 =

1.

D700 Pump/systemdata error Pump input data are invalid ● Check plausibility of values in P‑0‑1389[160→

174]

D702 Velocity/torquepolarity scalingerror

Scaling error

● The polarity of torque and velocity has to beidentical (S‑0‑0043 & S‑0‑0085).For pumps with clockwise rotation (R type), thepolarity has to be negative. For pumps with anti‐clockwise rotation (L type), the polarity has to bepositive. Otherwise, the pump might be dam‐aged during operation.

D703 SYX functionalpackage Error

SYX functional package not ena‐bled

● Enable SYX functional package (P‑0‑2003; bit7).

Tab. 7-70: TroubleshootingIn all error cases, MLD reset ("Reset Warm", P‑0‑1350; bit 4) or clearing ofthe error at the drive (drive command C0500)1) causes the error to be clearedand the project data to be reset.If the cause of the error has not been resolved, the error will occur again andthe drive changes to phase 2 "AB".

Fig. 7-11: Resetting MLD

1) As an alternative, the command for resetting error messages can be triggered bypressing the Esc key at the control panel of the drive controller!




Furthermore:● Bit 10 in P‑0‑1390 can be used to reset the error state.● Bit 24 in configuration word P‑0‑1370 deactivates warning

E2017.

P‑0‑1370Bit 24

Allow notices by warning E2017

0: On

1: Off

Code(P-0-1300)

Description ofwarning(P-0-1387)

Cause Remedy

B104 Positive speedlimit active

Speed command value (P/Q con‐troller output) is too high, the valueis limited to the maximum allowedpositive speed of the pump to avoidmechanical wear.

B105 Negative speedlimit active

Speed command value (P/Q con‐troller output) is too low, the valueis limited to the minimum allowedspeed of the pump to avoid me‐chanical wear.

● Since many pump types have bipolar speed limi‐tations, the internal value of this feature simply isthe negation.

● The feedback value of this limitation is 0, if thepressure at the pump output (sensor return) isvery low to avoid cavitation.

B106 Upper powerlimit active

Pump is severely loaded (highspeed at almost maximum pres‐sure).

● Check the pump data defined in the software/parameter file. P‑0‑1389[163].

● Check the oil quality, since it can generate ahigh friction torque.

B107Acceleration/deceleration limitactive

The difference of the speed com‐mand value (p/Q controller output)is limited.

● Check the pump data defined in the software/parameter file, P‑0‑1389[168].Note: if data input = 0 → no values are taken intoaccount

● Compare current torque S‑0‑0084 (pressure-de‐pendent) to P‑0‑0442, P‑0‑0443 that have an ef‐fect on the available acceleration torque (→ op‐tional dynamic acceleration limitation).

● The dynamic acceleration is disabled ifP‑0‑1370; bit 17 = 1.

B108 Low positivespeed

The current positive speed is toolow. Thus, the pump cannot contin‐uously maintain the pressure.

● This monitoring function is an integral part of theinternal thermal pump model that is deactivatedif P‑0‑1370; bit 23 = 1 or if the model does notcontain any data.

● If the pump is operated in this speed range, thiscan cause mechanical wear due to the so-called“stick-slip effect“.

B109 Risk of heat ac‐cumulation

The pump heats up dangerously!Estimated degree of heat P‑0‑1298> 90 %.

● Operate at a speed above the value inP‑0‑1297.

● This monitoring is disabled if P‑0‑1370, bit 23 =1.

166/183




Code(P-0-1300)

Description ofwarning(P-0-1387)

Cause Remedy

B201 High pressurelevel

The pressure feedback value isgreater than the threshold inP‑0‑1389[103].The pressure feedback value isgreater than the maximum permis‐sible continuous pressure inP‑0‑1389[176].

● If P‑0‑1389[103] = 0, this optional monitoringfunction is disabled.

B202 Low pressurelevel

The pressure feedback value islower than the threshold inP‑0‑1389 [104].The pressure feedback value issmaller than the minimum permissi‐ble continuous pressure inP‑0‑1389[177].

● If P‑0‑1389 [104] = 0, this optional monitoringfunction is disabled.

B203Pressure com‐mand value limitactivated

The pressure command value islimited to:Max.: min. (P‑0‑1389[101],P‑0‑1389 ... [175])Min.: max. (P‑0‑1389 [102],P‑0‑1389 [177])

● User-defined restrictions (P‑0‑1389 [101], [102])are ignored if = 0.

B204Flow commandvalue limit acti‐vated

The flow command value is limitedto:Max.: P‑0‑1389 [110] (only duringcommissioning)Min.: P‑0‑1389 [111]

B205Pressure sensorsignal relativelylow

The plausibility check of the pres‐sure sensor signal compared to theactual torque shows a deviationgreater than the deviation set inP‑0‑1389 [141].

● If P‑0‑1389 [141] = 0, this warning is disabled.● If the oil quality is poor (high friction), the warn‐

ing threshold can be increased. But first of all itis necessary to check whether the sensor hasbeen correctly installed in the machine.

Tab. 7-71: Troubleshooting




8 Annex8.1 Documentations8.1.1 Drive systems, system components

Drive systems with single-axis or double-axis drive controllers

Title Type of documentation Documentation type1) Material number

Drive system – Rexroth IndraDriveComplete, intelligent and safe

Product catalog R999000019 R999000019

Rexroth IndraDrive CsDrive systems with HCS01

Project Planning Manual DOK-INDRV*-HCS01******-PRxx-EN-P

R911322210

Rexroth IndraDriveDrive systems with HMV01/02,HMS01/02, HMD01, HCS02/03

Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P

R911309636

Rexroth IndraDriveSupply Units, Power Sections HMV,HMS, HMD, HCS02, HCS03

Project Planning Manual DOK-INDRV*-HMV-S-D+HCS-PRxx-EN-P

R911318790

Rexroth IndraDriveControl sections CSE02, CSB02,CDB02, CSH02

Project Planning Manual DOK-INDRV*-Cxx02******-PRxx-EN-P

R911338962

Rexroth IndraDriveAdditional components and accesso‐ries

Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P

R911306140

1) In the documentation types, "xx" is a placeholder for the currentdocumentation version (example: PR01 means the first editionof a project planning description)

Tab. 8-1: Documentation – Drive systems, system components

8.1.2 FirmwareTitleRexroth IndraDrive ...

Type of documentation Document typecode1)

DOK-INDRV*-…

Material numberR911…

MPx-20Functions

Application Manual MP*-20VRS**-APxx-EN-P 345608

MPx-20Version Notes

Release Notes MP*-20VRS**-RNxx-EN-P 345606

Power Supply Basic PSB-20Functions

Application Manual PSB-20VRS**-APxx-EN-P 345610

Power Supply Basic PSB-19Functions

Application Manual PSB-19VRS**-APxx-EN-P 345602

MPx-18Functions



Annex


TitleRexroth IndraDrive ...

Type of documentation Document typecode1)

DOK-INDRV*-…

Material numberR911…

MPx-18Version Notes


MPx-17Functions


MPx-17Version Notes


MPx-16Functions


MPx-16Version Notes


MPx-16 to MPx-20 and PSBParameters

Reference Book GEN1-PARA**-RExx-EN-P 328651

MPx-16 to MPx-20 and PSBDiagnostic Messages

Reference Book GEN1-DIAG**-RExx-EN-P 326738

Integrated Safety Technology"Safe Torque Off" (as of MPx-16)

Application Manual SI3-**VRS**-APxx-EN-P 332634

Integrated Safety Technology"Safe Motion" (as of MPx-18)

Application Manual SI3*SMO-VRS-APxx-EN-P 338920

Rexroth IndraMotion MLDLibraries as of MPx-17

Reference Book MLD-SYSLIB2-RExx-EN-P 332627

Rexroth IndraMotion MLDLibraries as of MPx-18

Reference Book MLD-SYSLIB3-RExx-EN-P 338916

Rexroth IndraMotion MLDas of MPx-17

Application Manual MLD2-**VRS*-APxx-EN-P 334351

Rexroth IndraMotion MLDas of MPx-18

Application Manual MLD3-**VRS*-APxx-EN-P 338914

1) In the document typecodes, "xx" is a placeholder for the currentedition of the documentation (e.g.: RE02 is the second editionof a Reference Book)

Tab. 8-2: Documentations – Firmware

8.1.3 Motor-pump unit


SytronixVariable-speed pump drives

Product catalog R999000332 R999000332

Rexroth Sytronix SvP 70xxMotor-Pump Unit MPA01

Operating Instructions DOK-SYTROX-MPA01******-ITxx-xx-P

R911339824

170/183

Annex




Rexroth Sytronix SvP 70xxMotor-pump unit MPA02

Operating instructions DOK-SYTROX-MPA02******-ITRS-EN-P

R911387041

Rexroth Sytronix SvP 7020 IMCVariable-Speed Pump Drives

Operating instructions DOK-SYTROX-SVP7020-I*C-ITxx-EN-P

R911377189

Rexroth Sytronix SvP 7020 PFCVariable-Speed Positioning of Hy‐draulic Axes

Operating instructions DOK-SYTROX-SVP7020-PF*-ITxx-EN-P

R911377195

Rexroth Sytronix SvP 7020 PFC Vari‐able-Speed Positioning of HydraulicAxes

Commissioning Manual DOK-SYTROX-SVP7020-PF*-CO R911379550

Rexroth Sytronix SvP 7020 IMC Vari‐able-Speed Pump Drives

Commissioning Manual DOK-SYTROX-SVP7020-I*C-CO R911376149

1) In the document type codes, "xx" is a placeholder for the cur‐rent edition of the documentation (e.g.: IT01 is the first editionof Operating Instructions)

Tab. 8-3: Documentations – motor-pump unit

8.2 AbbreviationsADC Analog-digital converter

AF Drive enable

AT Cyclic actual values

AU Drive in automatic mode

DAC Digital-analog converter

DFEn Variable-speed drive using a pump with electronic pressureand flow rate control

DRn Constant pressure system with hydromechanical pressurecontrol

EMC ElectroMagnetic Compatibility

F_act Actual force value

F_cmd Force command value

FcP Frequency-controlled pump

FW Drive firmware (e.g., MPx20VRS)

FOC mode Field-oriented current control with motor encoder

FXC mode Flux-controlled, sensorless motor operation

HW Hardware

IMC Injection Molding Control (p/Q control)

IW IndraWorks

MDT Cyclic command values

MLC Motion Logic Control

MLD Motion Logic Drive-based


Annex


MPx Drive firmware

Decimal places Decimal places

n_act Actual speed value

P_act Actual pressure value

P_cmd Pressure command value

PFC Position Force Control (x/F control)

Q_act Actual flow value

Q_cmd Flow command value

SvP Servo-variable pump

SW Software/parameter file (MLD program,FWS_MLDSYx_xxx_xxx)

SYX SYTRONIX technology function

Vg Displacement per revolution

Tab. 8-4: Basic abbreviations

8.3 Data entry pump for IMCThe software/parameter file contains data sheets for various Rexroth pumptypes for use with SvP systems.

Configuration The code in P‑0‑1389[100] determines the pump type connected to the motoras follows:

Code Type Model

0 Standard, internal gear pump PGH4-3X/020

1 ... 19 Reserved

20 Internal gear pump PGH2-2X/005



23 ... 29 Reserved




33 ... 39 Reserved







46 ... 49 Reserved

172/183

Annex



Code Type Model








57 ... 59 Reserved

100 Axial piston pump* A10FZO/006



* No internal data available for monitoring of the thermal stability.Tab. 8-5: Code in P‑0‑1389 [100] for supported pump typesFor other types, enter P‑0‑1389[100] = 200 (or another value not specifiedabove); then use P‑0‑2943 to manually configure the most important proper‐ties.

The manually entered data will be acceptedwithout further verification. A faulty settingmay cause damage in the pump

WARNING

Inputs / outputs P‑0‑1389[160 → …] are reserved for the display of the most important, cur‐rently active data or the entry of pump types which are not integrated.P‑0‑1389...[160]: Vg1, cm³ (displacement)[161]: Vg2, cm³ (for variable displacement pumps/double pumps)[162]: Reserved![163]: Maximum input power, kW[164]: Moment of inertia with regard to drive axis, gm²[165]: Max. bipolar speed, rpm[166]: Min. positive speed, rpm[167]: Reserved![168]: Max. bipolar acceleration, rad/s²[169]: Reserved![175]: Max. critical pressure, bar[176]: Max. admissible continuous pressure, bar[177]: Min. admissible continuous pressure, bar


Annex


If one field of the manually entered data is invalid and the drive isswitched to AF, error D700 will be generated in order to preventthe operation. In this case, check the feasibility of the data inP‑0‑1389[160→…] , subsequently switch to AF;P-0-2943: has to be > 0P-0-1389[163]: must be > 0P-0-1389[164]: must be > 0P-0-1389[165]: must be > 0P-0-1389[166]: must be > 0 and < P-0-1389[165]P-0-1389[168]: must be > 0P-0-1389[175]: must be > 0 and < P-0-1389[166]P-0-1389[176]: must be > 0 and < P-0-1389[167]P-0-1389[177]: must be > 0


Code (P‑0‑1300) D700

Text (S‑0‑0095 or P‑0‑1387) Pump/sys. data error

174/183

Annex



9 Service and supportContact for repairs Bosch Rexroth AG

Service IndustriehydraulikBürgermeister-Dr.-Nebel-Straße 897816 Lohr am MainPhone +49 (0) 93 52 / 40 50 60Germany

E-mail: [email protected]: http://www.boschrexroth.com/service

Contacts for support Bosch Rexroth AGZum Eisengießer 197816 Lohr am MainGermany

E-mail: [email protected]

Required information We can provide fast and efficient assistance, if you have the following infor‐mation at hand:● Detailed description of the fault and the circumstances● Details on the nameplate of the affected products, especially type code

and serial number● Your contact details (phone and fax number, e-mail address)


Service and support




IndexSymbols- EtherNet/IPTM ................................................. 46[0] to [70] parameter set memory (4 sets)

P-0-1311...................................................... 128

AAbbreviations.................................................... 171Acceleration limitation of pump speed

P-0-1329...................................................... 144Acceleration limitations..................................... 112Acceleration ramp

Flow command value..................................... 76Accessories........................................................... 5Action symbols.................................................... 17Activate EtherCAT® (CoE)................................. 51Activate EtherCAT® (SoE).................................. 49Activate PROFIBUS®......................................... 41Activate PROFINET®......................................... 44Activate Sercos®................................................ 52Active pressure command value

P-0-1271...................................................... 120Actual degree of heat

P-0-1298...................................................... 127Additional documentations................................ 169Analog interface for the external control............. 64Annex................................................................ 169Application type................................................... 21Automatic internal injection function................... 90Axis control (open-loop and closed-loop).............. 4

BB7xx.................................................................. 164B104.................................................................. 163B105.................................................................. 163B106.................................................................. 163B107.................................................................. 163B108.................................................................. 163B109.................................................................. 163B201.................................................................. 163B202.................................................................. 163B203.................................................................. 163B204.................................................................. 163B205.................................................................. 163Basic protection settings/default values.............. 99

CCam status word

P-0-1411...................................................... 158Cam, switch-off threshold

P-0-1319...................................................... 139Cam, switch-on threshold

P-0-1318...................................................... 138Click.................................................................... 17Commissioning................................................... 29

Communication interface............................... 58

I/O configuration............................................. 58Commissioning tool

IndraWorks Ds/D/MLD..................................... 6Configuration

P-0-1370...................................................... 145Configuring IndraDrive........................................ 35Configuring the drive

Ethernet connection....................................... 29Connection to the control.................................... 35Constant pressure systems.................................. 4Control

Connection..................................................... 35Control word

P-0-1390...................................................... 156Controller output limitation, negative

P-0-1378...................................................... 151Current control

Parameter setting........................................... 79

DD100................................................................. 163D101................................................................. 163D201................................................................. 163D202................................................................. 163D203................................................................. 163D205................................................................. 163D700................................................................. 163D701................................................................. 163D702................................................................. 164D703................................................................. 164Deceleration limitation of pump speed

P-0-1330...................................................... 144Diagnostic memory............................................. 95Diagnostics

IMC.............................................................. 163Diagnostics including logbook............................. 95Disturbance observer term, limited

P-0-1278...................................................... 122Documentation

Additional documentations........................... 169Overview...................................................... 169Record of revisions.......................................... 1Reference documentations.......................... 169

Double click ........................................................ 17Double pump....................................................... 79Double pump operation....................................... 79Drag ................................................................... 17Drop ................................................................... 17Dynamic master/slave mode............................... 87

EE2011................................................................ 163E2012................................................................ 163E2013…16........................................................ 163E2017................................................................ 164


Index

Effective flow command valueP-0-1285...................................................... 124

Effective max. velocity limitationP-0-1289...................................................... 125

Effective min. velocity limitationP-0-1290...................................................... 125

Electrical system characteristics......................... 25Error/warning code

P-0-1300...................................................... 127Error/warning history

P-0-1312[0 ... 99]......................................... 137Errors................................................................ 163

Error messages, IMC................................... 163Establishing the connection................................ 29Establishing the connection to the drive con‐troller................................................................... 29

Establishing the connection........................... 29General information....................................... 29Requirements................................................. 29

Ethernet connection............................................ 29Extended setting

IMC................................................................ 79External control

Analog interface............................................. 64

FF2011................................................................ 163F2012................................................................ 163F2013…16........................................................ 163F2017................................................................ 163Factor of speed switching threshold for cam

P-0-1326...................................................... 142Filter time constant 2 switching threshold

P-0-1311[201].............................................. 132Firmware packages

Important features............................................ 6Flow command value

Limitation...................................................... 111P-0-1377...................................................... 150

Flow feedback valueP-0-1301...................................................... 128

Freely selectable parameter sets........................ 82Functional features............................................. 27

II - integral action time 2

P-0-1311 [200]............................................. 130I-integral action time

P-0-1374...................................................... 148I-integral action time, set 2

P-0-1321...................................................... 140I-term

Switch............................................................ 93IMC

Communication/interface............................... 57Diagnostics.................................................. 163Error messages............................................ 163

Extended setting............................................ 79Initial commissioning...................................... 55Warnings...................................................... 163

IMC commissioning............................................. 54IMC control: D-component/disturbance ob‐

server factorP-0-1375...................................................... 149

IMC control: Lower limitation of disturbanceobserver

P-0-1331...................................................... 145IMC control: P-gain

P-0-1373...................................................... 148IMC controller

Parameter setting........................................... 69IMC controller cycle time

P-0-1276...................................................... 122IMC controller structure....................................... 69IMC library........................................................... 22IndraMotion MLD

Functional package/license............................ 22IndraWorks Ds/D/MLD.......................................... 6Initial commissioning

IMC................................................................ 55Injection: Final speed, injection function

P-0-1327...................................................... 143Injection: Pressure ratio, beginning of ramp,

inject. phase speed limitP-0-1311 [210]............................................. 136

Injection: Pressure ratio, end of ramp, injec‐tion phase speed limit

P-0-1311 [211]............................................. 137Injection: Smoothing time constant

P-0-1324...................................................... 142Internal injection function.................................... 90Introducing the product

Sytronix DFE – variable-speed drive us‐ing a pump with electronic pressure andflow rate control................................................ 3Sytronix DRn – constant pressure systemwith hydromechanical pressure control............ 3Sytronix FcP – frequency-controlledpump drive....................................................... 3Sytronix SvP – servo-variable pump drive....... 3

Introduction and basic principles of IMC............. 21

LLeakage compensation....................................... 91Leakage compensation, determination pressure

P-0-1311[209].............................................. 135Leakage compensation, determination speed

P-0-1311[208].............................................. 134Loading IMC project............................................ 34Loading project................................................... 34Loading the basic settings

Default values................................................ 55Logbook.............................................................. 95Lower limitation of D component

178/183

Index


P-0-1383...................................................... 152Lower safe velocity limit

P-0-1295...................................................... 125

MMaster communication........................................ 35

Select............................................................. 40Set.................................................................. 40

Master mode....................................................... 87Master/slave mode.............................................. 86

Configuration.................................................. 90Max. safe positive speed limitation

P-0-1296...................................................... 126Min. safe positive speed limitation

P-0-1297...................................................... 126Minimum speed in slave operation

P-0-1311[204].............................................. 134Monitoring functions

Configuration.................................................. 96

NNote ................................................................... 18

OObligations.......................................................... 14Overview............................................................. 54

PP-gain – set 2

P-0-1320...................................................... 140Parameter description....................................... 120

P-0-1271, Active pressure command val‐ue................................................................. 120P-0-1275, Pump displacement - effective.... 121P-0-1276, IMC controller cycle time............. 122P-0-1278, Disturbance observer term,limited........................................................... 122P-0-1280, Upper limit of disturbance ob‐server, effective............................................ 122P-0-1281, Swivel angle feedback value....... 123P-0-1282, Speed command value inslave operation (master communication)..... 123P-0-1285, Effective flow command value..... 124P-0-1289, Effective max. velocity limita‐tion............................................................... 125P-0-1290, Effective min. velocity limita‐tion .............................................................. 125P-0-1295, Lower safe velocity limit ............. 125P-0-1296, Max. safe positive speed limi‐tation............................................................ 126P-0-1297, Min. safe positive speed limita‐tion............................................................... 126P-0-1298, Actual degree of heat.................. 127P-0-1299, Safe acceleration limitation......... 127P-0-1300, Error/warning code...................... 127P-0-1301, Flow feedback value................... 128P-0-1311 [200], I - integral action time 2...... 130

P-0-1311, [0] to [70] parameter set mem‐ory (4 sets)................................................... 128P-0-1311[201], Filter time constant 2switching threshold...................................... 132P-0-1311[204], Minimum speed in slaveoperation...................................................... 134P-0-1311[208], Leakage compensation,determination speed.................................... 134P-0-1311[209], Leakage compensation,determination pressure................................ 135P-0-1311[210], Injection: Pressure ratio,beginning of ramp, inject. phase speedlimit............................................................... 136P-0-1311[211], Injection: Pressure ratio,end of ramp, injection phase speed limit...... 137P-0-1312[0 ... 99], Error/warning history...... 137P-0-1318, Cam, switch-on threshold............ 138P-0-1319, Cam, switch-off threshold............ 139P-0-1320, P-gain – set 2.............................. 140P-0-1321, I-integral action time, set 2.......... 140P-0-1322, ParaSet: Switch point, set 2........ 141P-0-1323, ParaSet: Switch point, set 1........ 141P-0-1324, Injection: Smoothing time con‐stant............................................................. 142P-0-1326, Factor of speed switchingthreshold for cam......................................... 142P-0-1327, Injection: Final speed, injectionfunction........................................................ 143P-0-1329, Acceleration limitation of pumpspeed........................................................... 144P-0-1330, Deceleration limitation of pumpspeed........................................................... 144P-0-1331, IMC control: Lower limitation ofdisturbance observer................................... 145P-0-1370, Configuration............................... 145P-0-1373, IMC control: P-gain..................... 148P-0-1374, I-integral action time.................... 148P-0-1375, IMC control: D-component/disturbance observer factor......................... 149P-0-1376, Upper limitation of disturbanceobserver....................................................... 150P-0-1377, Flow command value.................. 150P-0-1378, Controller output limitation,negative....................................................... 151P-0-1383, Lower limitation of D compo‐nent.............................................................. 152P-0-1384, PT1 command value filter, fil‐ter time constant, ascent.............................. 152P-0-1385, PT1 command value filter, fil‐ter time constant, descent............................ 153P-0-1387, Sytronix message text................. 153P-0-1389, [100 ... 200] Protective func‐tion parameters............................................ 154P-0-1390, Control word................................ 156P-0-1410, Status word................................. 157P-0-1411, Cam status word......................... 158P-0-1415, SF warnings................................ 159P-0-1416, SF error messages...................... 160


Index

S-0-0800, Pressure command value........... 160S-0-0813, System pressure......................... 161S-0-0827, Pressure control deviation........... 161S-0-0832, Pressure window......................... 162

Parameter set switching...................................... 81Enable............................................................ 83

Parameter settingIMC controller................................................. 69

Parameters and diagnostic messages forp/Q control injection molding (IMC)................... 119ParaSet: Switch point, set 1

P-0-1323...................................................... 141ParaSet: Switch point, set 2

P-0-1322...................................................... 141Personnel............................................................ 10PID

Settings.......................................................... 72Pipe damage

Detection...................................................... 113Power limitation................................................. 105Pressure command value

S-0-0800...................................................... 160Pressure command value (p_command)

Filter settings.................................................. 71Pressure control deviation

S-0-0827...................................................... 161Pressure limitation............................................ 101Pressure monitoring.......................................... 101Pressure sensor interface (CSB)

Configuration.................................................. 61Pressure sensor interface (CSH)

Configuration.................................................. 58Pressure sensor interface (HCS01)

Configuration.................................................. 63Pressure sensor monitoring

Detection...................................................... 114Pressure window

S-0-0832...................................................... 162Protective function parameters

P-0-1389..., [100 ... 200].............................. 154Protective functions

Configuration.................................................. 96PT1 command value filter, filter time con‐

stant, ascentP-0-1384...................................................... 152

PT1 command value filter, filter time con‐stant, descent

P-0-1385...................................................... 153Pump displacement - effective

P-0-1275...................................................... 121

QQ_command

Settings acceleration ramp............................ 76Qualification........................................................ 10

RRange of applications........................................... 4Reference documentations............................... 169Relevant parameters......................................... 119Requirements

Hardware and firmware.................................... 7Right click ........................................................... 17

SSafe acceleration limitation

P-0-1299...................................................... 127Safety

General.......................................................... 10Product and technology................................. 11

Setting the IP address using the control panel... 33SF error messages

P-0-1416...................................................... 160SF warnings

P-0-1415...................................................... 159Software packages

Parameter files................................................. 7Software/parameter file (*.par)............................ 34Software/parameter file packages........................ 6Software/parameter files

Type code........................................................ 7Speed command value in slave operation

(master communication)P-0-1282...................................................... 123

Speed limitation................................................ 107Status word)

P-0-1410...................................................... 157Support

See Service Hotline..................................... 175Swivel angle feedback value

P-0-1281...................................................... 123Symbols.............................................................. 17

Keyboard........................................................ 18Other ............................................................. 18

System characteristics........................................ 25System components........................................... 21System function.................................................. 25System pressure

S-0-0813...................................................... 161System requirements.......................................... 21Sytronix components............................................ 5Sytronix message text

P-0-1387...................................................... 153Sytronix system overview..................................... 1

TText input............................................................ 18Thermal monitoring........................................... 108Time constant

Switch............................................................ 93Troubleshooting................................................ 164Troubleshooting guide...................................... 164

B104............................................................. 166

180/183

Index


B105............................................................. 166B106............................................................. 166B107............................................................. 166B108............................................................. 166B109............................................................. 166B201............................................................. 167B202............................................................. 167B203............................................................. 167B204............................................................. 167B205............................................................. 167D100............................................................ 164D101............................................................ 164D201............................................................ 164D202............................................................ 164D203............................................................ 164D205............................................................ 165D700............................................................ 165D702............................................................ 165D703............................................................ 165

Two-point control................................................ 79

UUpper limit of disturbance observer, effective

P-0-1280...................................................... 122Upper limitation of disturbance observer

P-0-1376...................................................... 150

VVelocity controller

Parameter setting........................................... 77

WWarnings

IMC.............................................................. 163


Index

Notes


Bosch Rexroth AGIndustrial HydraulicsZum Eisengießer 197816 Lohr, GermanyPhone +49 9352 [email protected]

*RE 62311-IB/11.2019*RE 62311-IB/11.2019

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