Proportional directional valve, direct operated, with pQ functionality

Proportional directional valve, direct operated, with pQ functionality
Proportional directional valve,
direct operated,
with pQ functionality
1/18
RE 29014/06.05
Replaces: RE 29014-02-M
Type STW 0195, type STW 0196
STW 0195:
Size 6
Component series 2X
STW 0196:
Size 10
Component series 1X
H6857_d
Table of contents
Contents
Features
Page
Features
1
Ordering code
2
Standard types, symbols
2
Structure, function, section
3
Technical data
Electrical connection, pin assignment
Characteristic curves
Unit dimensions
4 and 5
– Direct operated 3-way proportional valve with integrated digital
closed-loop control electronics type IAC-P, for controlling a
pressure in port A
– Completely matched unit, consisting of a position-controlled
valve, pressure sensor and field bus interface
– Actuation via proportional solenoid with central thread and
detachable coil
5 to 7
– Closed-loop position controlled valve spool
8 to 13
– Integrated pressure sensor plate (optional)
14 and 15
– For subplate mounting: Porting pattern to ISO 4401
Accessories (not included in the scope of supply)
16
– Analogue interfaces for command and actual values
Accessories
17
– Version for CAN bus with CANopen protocol DS 408 or
Profibus DP
Engineering / maintenance notes / supplementary information 18
– Separate component plugs for power supply and bus interfacing
– Fast commissioning by means of PC and commissioning software WINPED
2/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Ordering code
STW
0195
2X
V
24
*
With integrated digital electronics and pQ functionality
Size 6
Further details
in clear text
Component series 20 to 29
= 2X
(20 to 29: unchanged installation and connection dimensions)
Nominal flow
P → A 10 l/min, A → T 20 l/min
P → A 20 l/min, A → T 20 l/min
A6 =
F6 =
=1
=2
FKM = rectangular profile rings suitable for mineral oils
(HL, HLP) to DIN 51524
Bus interface
CAN bus DS - 408
Profibus DP V0/V1
C=
P=
Supply voltage
24 VDC
=V
24 =
3=
5=
8=
STW
0196
1X 1
V
Pressure stage of the integrated pressure
sensor
Nominal pressure 50 bar
Nominal pressure 160 bar
Nominal pressure 250 bar
24
*
With integrated digital electronics and pQ functionality
Size 10
Further details in clear
text
Component series 10 to 19
=1X
(10 to 19: unchanged installation and connection dimensions)
Nominal flow
P → A 65 l/min,
A → T 60 l/min,
B → T 60 l/min
A6 =
F6 =
=V
Supply voltage
24 VDC
24 =
3=
5=
8=
Interface A6 or F6
±10 VDC
4 to 20 mA
Bus interface
CANBus DS - 408
Profibus DP V0/V1
C=
P=
=1
FKM = rectangular profile rings suitable for mineral oils
(HL, HLP) to DIN 51524
Interface A6 or F6
±10 VDC
4 to 20 mA
Pressure stage of the integrated pressure
sensor
Nominal pressure 50 bar
Nominal pressure 160 bar
Nominal pressure 250 bar
Standard types, symbols
Type
Size
Material no.
STW 0195-2X/1V5-24CF6
STW 0195-2X/1V8-24CF6
6
6
R900767353
R901018622
STW 0195-2X/2V5-24CF6
STW 0195-2X/2V8-24CF6
6
6
R901006499
R901006529
STW 0196-1X/1V5-24CF6
STW 0196-1X/1V8-24CF6
10
10
R900705778
R901021786
Symbol
A
B
G
a
b
P
P
T
A
B
G
a
b
P
P
T
RE 29014/06.05
Hydraulics Bosch Rexroth AG
STW0195, STW0196
3/18
Structure, function, section
Structure
The digital integrated control electronics allow the following
faults to be detected: (Diagnosis)
– Cable break of pressure sensor supply cable (6)
– Undervoltage
– Break of position transducer cable (5)
– Communication error
– Watchdog
– Cable break of command value inputs
The IAC-P valve basically consists of:
– Housing (1) with mounting face
– Control spool (2) with compression spring (3)
– Solenoid and pressure tube (4) with central thread
– Position transducer (5)
– Pressure sensor (6)
– Integrated digital closed-loop control electronics IAC-P (7)
with bus interface (X2) and central plug-in connector (X1).
– With de-energised solenoid (4), spool position A → T
(with STW 0196-1X/1 additionally B → T)
The following additional functions are available:
– Pressure ramp
– Internal command value profile
– Enable function analogue / digital
– Functions:
– Fault output 24 V
Functional description
• Open-loop flow control (Q)
• Closed-loop pressure control (p)
• Alternating closed-loop control p/Q
PC program WINPED
For performing engineering work and parameterising the IACP valves, the user can utilize the commissioning software
WINPED (see Accessories).
– The command value can be fed forward alternatively via an
analogue interface (X1) or via the field bus interface (X2, X3).
- Parameterisation
– The actual value signals are made available via an analogue
interface (X1) and can be read out additionally via the field
bus (X2, X3).
- Diagnosis
- Comfortable data administration on a PC
– The controller parameters are adjusted via the field bus (X2,
X3).
- PC operating systems: Windows 2000 or Windows XP
– For safety reasons, separate supply voltage for bus/controller
and power part (output stage)
Qcomm
Q open-loop control
p closed-loop control
< 12 mA
A→T
inactive
Alternating closed-loop control: (A → T or P → A)
Open-loop Q control (Qcomm) with pressure limitation (pcomm)
While pressure limitation is active, the following is valid: Qact ≤ Qcomm
> 12 mA
Functional section of STW 0195–2X
X2
X3 only available in conjunction with
Profibus
7
X1
X3
b
A
Note:
6
3
2
B
1
Draining of the tank line must be prevented. In the case of a corresponding installation situation, install a suitable pre-load valve.
4
5
4/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Technical data (for applications outside these parameters, please consult us!)
General
STW195
Installation orientation
STW196
Optional, preferably horizontal
Storage temperature range
°C –20 … +80
Ambient temperature range
°C –20 … +50
Weight
kg 2.4
6.5
Hydraulic (measured with HLP 46 at ϑoil = 40 °C ± 5 °C and p = 100 bar)
Operating pressure 1)
Ports P, A, B
Port T
with sensor
with sensor
Nominal flow qV nom
at ∆p = 5 bar
(see also flow characteristic
curves from page 10)
50 bar
bar 50
160 bar
bar 160
250 bar
bar 250
50 bar
bar 50
160 bar
bar 160
250 bar
bar 210
Spool 1
from P → A
l/min
from A → T
l/min
Spool 2
65
10
20
20
20
A → T, B → T
Max. flow
See characteristic curves and power limit from page 10
Hydraulic fluid
Mineral oil (HL, HLP) to DIN 51524,
further hydraulic fluids on enquiry
Hydraulic fluid temperature range
60
°C –20 … +80, preferably +40 … +50
mm2/s 20 … 380, preferably 30 … 46
Viscosity range
Max. permissible degree of contamination of the hydraulic fluid
- cleanliness class to ISO 4406 (c)
Class 20/18/15 2)
Hysteresis
% ≤ 0.1
Range of inversion
% ≤ 0.05
% ≤ 0.05
Response sensitivity
%10 K ≤ 0.15
Zero point drift
%100 bar ≤ 0.1
Electrical
Supply voltage
Nominal voltage
VDC 24
Upper limit value
VDC 19.4
Lower limit value
VDC 35
Max. permissible residual ripple content
Current consumption
Imax
A 2
Impulse current
A 3
Command value signals
Duty cycle 3)
Max. coil temperature
mA 4 … 20 or via CAN bus
% 100
4)
Type of protection of the valve to EN 60529
1)
Vss 2
°C up to 150
IP 65 with cable socket correctly mounted and locked
Operating pressure, due to valve and sensor
2) The
cleanliness classes specified for components must be adhered to in hydraulic systems. Effective filtration prevents malfunction and, at the same time, prolongs the service life of components. For the selection of filters, see data sheets RE 50070, RE
50076, RE 50081
3) Apply
4) Due
the supply voltage to the valve only, when required for the functional sequence of the machine.
to the surface temperatures of solenoid coils, observe European standards EN 563 and EN 982.
RE 29014/06.05
Hydraulics Bosch Rexroth AG
STW0195, STW0196
5/18
Technical data (for applications outside these parameters, please consult us!)
STW 195 (size 6) and STW 196 (size 10)
Sensors
Measuring range
p
bar
50
160
250
Overload protection
p
bar
120
320
500
Burst pressure
p
bar
550
800
1200
N
max
Matching error
Zero point
< 0.15 % of final value
Final value
< 0.3 %
Temperature coefficient in the nominal temperature range
Highest temperature coefficient of zero point
< 0.2 % / 10 K
Highest temperature coefficient of range
< 0.2 % / 10 K
Characteristic curve deviation
< 0.2 %
Hysteresis
< 0.1 %
Repeatability
< 0.05 %
Adjustment time (10 - 90%)
t < 2 ms
Long-term drift (1 year) under reference conditions
< 0.2 %
Conformity
CE to EMC Directives
89/336/EEC, 93/68/EEC, 93/44/EEC
Electrical connections, pin assignment
Component plug pin assignment X1, 11-pin + PE to DIN EN 175201-804
Pin
No. or litz
wire colour 1)
1
1
2
2
3
white
4
yellow
5
green
6
violet
7
pink
Pin assignment of interface A6
Pin assignment of interface F6
24 VDC (u(t) = 19.4 V … 35 V), Imax = 1.7 A (for output stage)
0V
load zero, reference for pins 1 and 9
Enable input 9 ... 35 V
±10 V command value Q
Ri > 50 kΩ
enable ON
Ri = 100 Ω
4...20 mA command value Q
Reference for command values Q and P
± 10 V actual value Q
4...20 mA actual value Q
0 … 10 V command value P Ri > 50 kΩ
0 … 10 V actual value P
(load impedance max. 300 Ω)
Ri = 100 Ω
4...20 mA command value P
red
brown
Control voltage, level like pin 1, Imax = 0.3 A (for signal part and bus)
10
black
0V reference potential for pins 3, 6, 8 and 11 (connected to pin 2 within the valve)
11
blue
Fault output 24 V (19.4 V … 35 V), 200 mA max. load
PE
green-yellow
Connected to heat sink and valve body
Connect shield to PE on the supply side only!
4...20 mA actual value P
(load impedance max. 300 Ω)
8
9
X1
4
5
10
3
1)
Litz wire colour of connecting cable for cable socket with cable set
(see Accessories )
9
6
11
7
2
1
8
6/18
Bosch Rexroth AG
Hydraulics
RE 29014/06.05
STW0195, STW0196
Electrical connections, pin assignment
Component plug assignment X2, CAN bus, (coding A), M12 x 1, 5-pin, male
Pin
Assignment
1
n.c.
2
n.c.
3
CAN_GND
4
CAN_H
5
CAN_L
Baud rate
Bus address
kbit/s
20 to 1000
1 to 127
CAN-specific settings:
The baud rate and the identifier must be set via the
bus system.
Assignment
1
+5V
2
RxD/TxD-N (A-cable)
3
D GND
4
RxD/TxD-P (B-cable)
5
Shield
3
2
5
4
1
Component plug-in connector pin assignment for Profibus DP, “X2“/”X3“ (coding B),
M12 x 1, 5-pin, male/female
Pin
X2
Baud rate
up to 12 MBaud
Bus address
1 to 126
X2
4
1
5
3
2
Setting via DIL switch
X3
4
3
The +5-V voltage of the IAC-P is available for an external terminating resistor.
1
5
2
Note:
We recommend that the shields be connected on both sides via the metal housings of the plug-in connectors.
The use of plug pins deteriorates the shield effect !
Internal shields are not required.
RE 29014/06.05
7/18
Hydraulics Bosch Rexroth AG
STW0195, STW0196
Electrical connections, pin assignment
Block circuit diagram, integrated control electronics
X2
Profibus
Profibus
controller
X3
Aternative
X2
X1
Command value Q 4
I
A
U
Command value p
7
I
A
U
Actual value Q
6
Actual value p
8
I
Fault output
11
Reference for pins
4; 7
I
10
24V load supply
1
24V signal supply
9
GND
2
Protective conductor
PE
Command value:
Actual pressure value
A
PWM
PID
PWM
Output
stage
U
I
U
D
Microcontroller
A
Actual position value
Oscillator
demodulator
=
≈
EEPROM
Flash
Cable break
GND
Output stage supply
DC
DC
+Ui
–Ui
GND
Command value 12 to 20 mA at pin 4 and reference potential at pin 5 causes a flow from P → A.
Command value 4 to 12 mA at pin 4 and reference potential at pin 5 causes a flow from A → T.
Actual value:
Actual value 12 to 20 mA at pin 6 and reference potential at pin 10 corresponds to a flow from P → A.
actual value 4 to 12 mA an Pin 6 and reference potential at pin 10 corresponds to a flow from A → T.
Connecting cable:
p
Output stage
OFF
5
Reference for pins
3; 6; 8; 11
D
D
Controller
U
3
CAN
controller
PWM
U
Enable
D
Valve with inductive position encoder
CAN bus
Recommendation:
– up to 25 m cable length for pins 1; 2 and PE: 0.75mm2, otherwise 0.25mm2
– up 50 m cable length for pins 1; 2 and PE: 1.00mm2
For outer diameters, see cable socket sketch
8/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
Characteristic curves of STW 0195-2X/1...
Stroke in % →
Transient function, STW 0195-2X/1..., A → T
100
0 - 100
100
75
0 - 75
75
50
0 - 50
50
25
0 - 25
25
0
0
0
20
40
0
20
40
Time in ms →
Stroke in % →
Transient function, STW 0195-2X/1..., P → A
100
0 - 100
100
75
0 - 75
75
50
0 - 50
50
25
0 - 25
25
0
0
0
20
40
0
Time in ms →
20
40
RE 29014/06.05
RE 29014/06.05
Hydraulics Bosch Rexroth AG
STW0195, STW0196
Characteristic curves of STW 0196-1X/1...
Stroke in % →
Transient function, STW 0196-1X/1..., A → T, B → T
100
0 - 100
75
0 - 75
75
50
0 - 50
50
25
0 - 25
25
100
0
0
0
40
80
0
40
80
Time in ms →
Stroke in % →
Transient function, STW 0196-1X/1..., P → A
100
0 - 100
75
0 - 75
75
50
0 - 50
50
25
0 - 25
25
100
0
0
0
40
80
0
Time in ms →
40
80
9/18
10/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Characteristic curves of STW 0195-2X/1... and STW 0196-1X/1...
Frequency response, STW 0195-2X/1...
5
–315
0
–270
–5
–225
–10
–180
–15
–135
–20
–90
–25
–45
Phase angle in ° →
Gain in dB →
10
±10%
±25%
±100%
0
–30
1
10
20
30
50
100
200
Frequency in Hz →
5
–315
0
–270
–3
–5
–225
–10
–180
–15
–135
–20
–90
–25
–45
–30
0
1
10
20
30
Frequency in Hz →
50
100
200
Phase angle in ° →
Gain in dB →
Frequency response, STW 0196-1X/1...
±10%
±25%
±100%
11/18
Hydraulics Bosch Rexroth AG
STW0195, STW0196
RE 29014/06.05
Characteristic curves of STW 0195-2X/1...
Performance limit P → A, closed-loop position controlled
120
70
100
60
50
80
Flow in l/min. →
Flow in l/min. →
Performance limit A → T, closed-loop position controlled
60
40
10
0
5
200
Pressure differential in bar →
50
100
150
5
250
100
150
200
250
Flow characteristic curve P → A, ∆p = 5 bar
12
25
10
Flow in l/min. →
20
15
10
5
0
- 100
50
Pressure differential in bar →
Flow characteristic curve A → T, ∆p = 5 bar
Flow in l/min. →
30
20
20
0
40
8
6
4
2
0
-80
-60
-40
Command value in % →
-20
0
0
20
40
60
Command value in % →
80
100
12/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Characteristic curves of STW 0195-2X/2...
Performance limit P → A, closed-loop position controlled
120
120
100
100
80
80
Flow in l/min. →
Flow in l/min. →
Performance limit A → T, closed-loop position controlled
60
40
40
20
20
0
60
5
50
100
200
150
0
250
5
Pressure differential in bar →
200
150
250
Flow characteristic curve P → A, ∆p = 5 bar
25
25
20
20
Flow in l/min. →
Flow in l/min. →
100
Pressure differential in bar →
Flow characteristic curve A → T, ∆p = 5 bar
15
10
15
10
5
5
0
- 100
50
0
-80
-60
-40
Command value in % →
-20
0
0
20
40
60
Command value in % →
80
100
RE 29014/06.05
Hydraulics Bosch Rexroth AG
STW0195, STW0196
13/18
Characteristic curves of STW 0196-1X/1...
Performance limit A → T, closed-loop position controlled
225
Performance limit P → A, closed-loop position controlled
250
225
200
200
175
150
Flow in l/min. →
Flow in l/min. →
175
125
100
75
150
125
100
75
50
50
25
25
0
5
50
100
150
200
Pressure differential in bar →
0
250
5
50
100
150
200
250
Pressure differential in bar →
Performance limit B → T, closed-loop position controlled
200
Flow characteristic curve A → T, ∆p = 5 bar
175
60
Flow in l/min. →
Flow in l/min. →
150
125
100
75
40
20
50
25
0
5
50
100
150
200
Pressure differential in bar →
0
-100
250
-40
-20
0
–20
0
Flow characteristic curve B → T, ∆p = 5 bar
60
60
Flow in l/min. →
Flow in l/min. →
-60
Command value in % →
Flow characteristic curve P → A, ∆p = 5 bar
40
40
20
20
0
-80
0
20
40
60
Command value in % →
80
100
0
–100
–80
–60
–40
Command value in % →
14/18
Bosch Rexroth AG
Hydraulics
RE 29014/06.05
STW0195, STW0196
Unit dimensions STW 0195-2X/1... (nominal dimensions in mm)
3
4
47
118
“X”
23
32
b
A
B
15,1
44
69
268
34
ca. 35
“X”
1
2
T
A
P
B
5
0,01/100mm
15
8
Rmax 4
F1
T
47
Required surface quality of
mating piece
A
P
F4
F2
B
G
F3
72
1 Valve housing
2 Proportional solenoid “b“ with inductive position transducer
3 Integrated digital control electronics
Subplates to data sheet RE 45052 and valve fixing screws
must be ordered separately.
Subplates:
G342/01(G3/8)
4 Nameplate
5 Machined valve mounting face
Position of ports to ISO 4401-03-02-0-94
Deviating from standard:
– Ports P, A, B and T Ø8 mm
– Bore G is not required, since the valve is not fitted
with a pin.
G341/01 (G1/4)
G502/01(G1/2)
Valve fixing screws:
4 off socket head cap screws
ISO 4762-M5 x 50-10.9
MT = 8.9 Nm
RE 29014/06.05
Hydraulics Bosch Rexroth AG
STW0195, STW0196
15/18
Unit dimensions STW 0196-1X/1... (nominal dimensions in mm)
3
4
144,6
”X”
20
40
72,5
b
19,1
40
69,3
92,2
ca.35
”X”
339
1
P
TA A
2
B TB
5
0,01/100mm
Rmax 4
50,8±0,2
72
32,5±0,2 13
20
Required surface quality of
mating piece
F1
F2
P
A
B
T
T1
F4
F3
94
1 Valve housing
2 Proportional solenoid “b“ with inductive position transducer
3 Integrated digital control electronics
Subplates to data sheet RE 45052 and valve fixing screws
must be ordered separately.
Subplates:
G66/01(G3/8)
G67/01(G1/2)
4 Nameplate
G534/01(G3/4)
5 Machined valve mounting face
Position of ports to ISO 4401-05-04-0-94
Deviating from standard:
Valve fixing screws:
– Port T1 is provided additionally
4 off socket head cap screws
ISO 4762-M6 x 40-10.9
MT = 15.5 Nm
16/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Accessories (not included in the scope of supply)
The following is required for parameterisa- CANopen
tion by means of a PC:
1
2
Interface converter (USB)
Profibus DP
VT-ZKO-USB/CA-1-1X/V0/0
VT-ZKO-USB/P-1-1X/V0/0
Mat. no. R901071963
Mat. no. R901071962
WINPED
Commissioning software
Download at www.boschrexroth.de\IAC
3
Connecting cable, 3 m
D-Sub / M12, coding A
D-Sub / M12, coding B
Mat. no. R900751271
Mat. no. R901078053
2
3
1
RE 29014/06.05
Hydraulics Bosch Rexroth AG
STW0195, STW0196
17/18
Accessories, port X1(not included in the scope of supply)
Cable socket for X1
Cable socket to DIN EN 17520-804
(11-pin + PE), plastic version
5
7
8
• Cable socket with cable set 2 x 5 m 12-pin
Material no. R900032356
• Cable socket with cable set 2 x 20 m 12-pin
Material no. R900860399
4
3
10
11
Material no. R900884671
33
6
• Cable socket without cable (kit)
2
9
1
90
Accessories, CAN bus (A coding) (not included in the scope of supply)
Description
Detail, dimensions
X2
Straight cable
socket, metal version.
ca. 56
1
2
Ø19,6
Round plug-in
connector,
wired by user, 5pin, M12 x 1
Pin pattern, order information
4
5
3
Mat. no.: R901076910
(cable diameter 6 - 8 mm)
Accessories, Profibus (B coding) (not included in the scope of supply)
Description
Detail, diemnsions
X2
Straight cable
plug, metal version.
ca. 61
M12 protective
cap (for cable
socket only)
3
2
ca. 56
4
3
Ø19,6
Straight cable
socket, metal version.
5
Mat. no.: R901075545
(cable diameter 6 - 8 mm)
X3
Round plug-in
connector,
wired by user, 5pin, M12 x 1
4
1
Ø19,6
Round plug-in
connector,
wired by user, 5pin, M12 x 1
Pin pattern, order information
5
2
1
Mat. no.: R901075550
(cable diameter 6 - 8 mm)
Mat. no.: R901075563
18/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Engineering / maintenance notes / supplementary information
Product documentation for STW0195, STW0196
Technical data sheet RE 29014 (this data sheet)
Operating manual RE 29015-B
CAN bus protocol description, RE 29015-01-Z
Profibus protocol description, RE 29015-02-Z
General information on maintenance and commissioning of hydraulic components
RE 07800 / RE 07900
Commissioning software WINPED and documentation on the Internet: www.boschrexroth.com/IAC
Maintenance notes:
– The units are tested in the factory and shipped with default settings.
– Only complete components can be repaired. The repaired components are returned again with the default settings.
User settings are not retained or reloaded. The user is responsible for reloading the corresponding user parameters.
Notes:
– Cut the supply voltage to the valve only in when required for the functional sequence of the machine.
– Electrical signals brought out via control electronics (e.g. signal “ready for operation”) must not be used for switching safety-relevant machine functions! (See also European standard “safety requirements for fluid power systems and components - hydraulics “, EN 982.)
– If electromagnet interference is to be expected, take suitable measures to safeguard the function (depending on application,
e.g. shield, filter)!
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application
can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process of
wear and aging.
RE 29014/06.05
STW0195, STW0196
Hydraulics Bosch Rexroth AG
19/18
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application
can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process of
wear and aging.
20/18
Bosch Rexroth AG
Hydraulics
STW0195, STW0196
RE 29014/06.05
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application
can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process of
wear and aging.
4/3 proportional directional valve
with integrated digital electronics
and field bus interface (IFB-P)
RE 29048/04.08
1/20
Type 4WREF
Sizes 6 and 10
Component series 2X
Maximum operating pressure 315 bar
Maximum flow 80 l/min (size 6) and 180 l/min (size 10)
tb0139
Table of contents
Features
Content
Page
Features
1
Ordering code
2
Standard types
2
Symbols
2
Function, section
3
Technical data
4
Integrated electronics (IFB-P)
Characteristic curves
Unit dimensions
Accessories
5 to 7
8 to 13
14 and 15
16 to 18
Engineering / maintenance notes / supplementary information 19
–Direct operated proportional directional valve with integrated
digital electronics and field bus interface (Integrated Field Bus
IFB-P)
–Actuation by proportional solenoids with central thread and
detachable coil
–Closed-loop position control of valve spool
–For subplate mounting: Porting pattern to ISO 4401
–Analog interface for command and actual value
–Command value (flow) analog or via bus
–Variant for CAN bus with CANopen protocol DS 408
or PROFIBUS DP
–Can be parameterized via bus
–Swift commissioning by means of PC and commissioning
software WIN-PED 6
2/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Ordering code
4WRE
F
2X V
24
*
=F
With integrated digital electronics
and field bus interface
=6
= 10
Size 6
Size 10
Symbols
A1 =
F1 =
A B
a
a
b
0
0
b
V =
=V
=W
W1
Nominal flow 2)
Size 6
8 l/min
16 l/min
32 l/min
Size 10
25 l/min
50 l/min
75 l/min
Supply voltage
24 VDC
24 =
=E
E1 1)
Electronics interface
±10 VDC
4 to 20 mA
Bus interface
CANBus DS-408
PROFIBUS DP V0/V1
C =
P =
P T
Further details in
clear text
FKM seals
Rectangular rings, suitable
for mineral oils (HL, HLP) to DIN 51524
2X =
= 08
= 16
= 32
Component series 20 to 29
(20 to 29: unchanged installation
and connection dimensions)
1) With
symbol E1:
P → A: qVmax
P → B: qV/2
B → T: qV/2
A → T: qVmax
= 25
= 50
= 75
2)See
flow characteristic curves from page 8 on.
Standard types
Material no.
Type
R901052649
4WREF 6 E32-2X/V-24CA1
R901125908
4WREF 6 E32-2X/V-24PA1
R901125909
4WREF 6 E32-2X/V-24PF1
Symbols
Type 4WREF . E…
G
Type 4WREF . V…
A B
a
G
b
P T
Type 4WREF . W…
A B
a
G
b
P T
A B
a
b
P T
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
3/20
Function, section
Structure:
System requirements
The valve basically consists of:
–IBM-PC or compatible system
–Housing (1) with connection face
–Control spool (2) with compression springs (3 and 4) and
spring plates (8 and 9)
–Windows 2000 or Windows XP
–RAM (recommendation 256 MB)
­­– Coils (5 and 6) and pole tubes (10 and 11) with central thread
–150 MB free hard disk space
­­–Position transducer (7)
Note
–Integrated digital electronics IFB-P (12)
–The PC program “WIN-PED“ is not included in the scope of
supply. It can be downloaded free of charge on the Internet
(see page 19)!
Functional description:
– When solenoids (5 and 6) are de-energized control spool
(2) is brought by compression springs (3 and 4) between
spring plates (8 and 9) to the central position (in the case of
V-spool without spring plate). With V-spools, the mechanical
zero position is not equal to the hydraulic one.
The integrated digital electronics allows the following
faults to be recognized:
–Undervoltage
–Cable break of position transducer (7)
–The electronics controls the valve spool position.
–Communication error
–The command value can be provided alternatively via an
analog interface (X1) or via the field bus interface (X2, X3).
–Watchdog
–The actual value signals are made available via an analog
interface (X1) and can additionally be read out via the field
bus (X2, X3).
– The controller parameters can be adjusted via the field bus
–Cable break of command value inputs (only in the case of
current interface)
The following additional functions are provided:
–Ramp generator
–Internal command value profile
PC program WIN-PED (version 6 or higher):
The commissioning software WIN-PED helps users solve engineering tasks and parameterize IFB-P valves.
–Enable function digital
–Overlap compensation
–Zero point correction
–Parameterization
–Diagnosis
–Convenient data administration on PC
–PC operating systems: Windows 2000 or Windows XP
X1
X2
12
X3
Note:
7
5
10 3
8
1
Draining of the tank line must be prevented. If the installation situation allows, install a suitable pre-load valve.
2
9
4
11
6
4/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Technical data (for applications outside these parameters, please consult us!)
General
Weight
Size 6
Size 10
2.4
6.5
kg
Installation orientation
Optionally, preferably horizontal
Storage temperature range
°C –20 to +80
Ambient temperature range
°C –20 to +50
Hydraulic (measured with HLP46, ϑoil = 40 °C ±5 °C)
Maximum operating
pressure
– Ports A, B, P
bar Up to 315
– Port T
bar Up to 210
Nominal flow qVnom at Δp = 10 bar
See nominal flow characteristic curve from page 8 ff.
l/min
Maximum flow (standard valves)
l/min
Hydraulic fluids
8; 16; 32
25; 50; 75
80
180
Mineral oil (HL, HLP) to DIN 51524
Other hydraulic fluids on request
Hydraulic fluid temperature range
°C –20 to +70, preferably +40 to +50
mm2/s 20 to 380, preferably 30 to 46
Viscosity range
Class 20/18/15 1)
Permissible max. degree of contamination of the
hydraulic fluid - cleanliness class to ISO 4406 (c)
Hysteresis (valve spool position control)
% ≤ 0.1
Range of inversion (valve spool position control)
% ≤ 0.05
Response sensitivity
(valve spool position control)
% ≤ 0.05
Zero point drift of valve spool when
hydraulic fluid temperature and operating
pressure change
%/10 K < 0.15
%/100 bar < 0.1
Electrical
Supply voltage
Nominal voltage
VDC 24
Lower limit value
VDC 19.4
Upper limit value
VDC 35
Permissible max. residual ripple Vss 2
A 2
Total current consumpImax
tion
Impulse current
A 3
Command and actual
Voltage “A1“
V ±10
value signals
Current “F1“
mA 4 to 20
Converter resolution (command/actual value signals)
Bit 10
Duty cycle 2)
Maximum coil temperature
% 100
3)
°C Up to 150
Type of protection to EN 60529
1) The
cleanliness classes specified for components must be
adhered to in hydraulic systems. Effective filtration prevents
malfunction and, at the same time, prolongs the service life
of components.
For the selection of filters, see data sheets RE 50070,
RE 50076 and RE 50081.
2) Do
not energize the valve unless this is required for the functional sequence of the machine.
3)Due
to the surface temperatures of solenoid coils observe
European standards EN 563 and EN 982!
IP 65 with plug-in connectors mounted and locked
Note!
For details regarding environment simulation testing in the
fields of EMC (electromagnetic compatibility), climate and
mechanical stress, see RE 29048-U (declaration on environmental compatibility).
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
5/20
Integrated electronics (IFB-P)
Marking and adjustment elements
A: + 24V DC
B: 0V
C: reference actual position
D: ±10V/0… 20mA
signal input
E: reference input
F: ±10V/0… 20mA
actual position
PE: earth conductor
1
1 Material no.
Rexroth
A B
G
*R901053294*
a
b
P T
4WREF6…
0000
A001
0000000 00
2
2 Production job order number
3
4
5
6
5 Type designation
3 Date of production
6 DIL switch for address and baud rate setting
(position B0 on the right-hand side)
4 Serial number
Electrical connections and pinout
Component plug pinout X1, 6-pin + PE to DIN EN 175201-804
Signal
Supply voltage
Actual value reference potential
Differential amplifier input
Measurement output
Contact
Pinout of interface A1
A
24 VDC (u(t) = 19.4 V to 35 V); Imax = 2 A
B
0 V
C
D
Actual value reference potential
E
F
Command value reference potential
±10 V actual valve spool value,
(limit load 5 mA)
1
n.c.
2
n.c.
3
CAN_GND
4
CAN_H
5
CAN_L
X2
Baud rate
kbit/s
20 to 1000
Bus address
1 to 127
Assignment
1
+5 V
2
RxD/TxD-N (A-line)
3
D GND
4
RxD/TxD-P (B-line)
5
Shield
X2
The +5 V voltage of the IAC-P is
used for supplying an external bus
terminator (as required).
1
X3
4
4
3
1
1 to 126
Settings by means of DIL switches.
5
2
1
MBaud up to 12
Bus address
3
4
5
4
The baud rate and the identifier can
be set via the bus system or using the
DIL switches.
Baud rate
X3
3
2
CAN-specific settings:
Component plug pinout for PROFIBUS DP, “X2“/”X3“
(coding B), M12, 5-pin, female/male
Pin
4 to 20 mA actual valve spool value,
load resistance max. 300 Ω
Connected to heat sink and valve body
Component plug pinout for CAN bus “X2“/”X3“ (coding A),
M12, 5-pin, male/female
Assignment
4 to 20 mA command value; Ri = 100 Ω
±10 V command value; Ri > 50 kΩ
PE
Pin
Pinout of interface F1
3
5
2
1
5
2
6/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Integrated electronics (IFB-P)
Settings for CANopen and PROFIBUS DP
CANopen
B7 B6 B5 B4 B3 B2 B1 B0
HEX
Baud rate: B7, B6
Address range: B5 to B0
0
0
0
0
0
0
0
0
00 1)
Standard 20 kBaud
or reprogrammed
1 = standard or
reprogrammed
0
0
0
0
0
0
1
1 to 63
0
1
1
1
1
1
01
to
3F
20 kBaud
0
0
to
1
0
1
0
0
0
0
0
0
40
125 kBaud
1 = standard or
reprogrammed
0
1
0
0
0
0
1
1 to 63
1
1
1
1
1
1
41
to
7F
125 kBaud
0
0
to
1
1
0
0
0
0
0
0
0
80
250 kBaud
1 = standard or
reprogrammed
1
0
0
0
0
0
1
250 kBaud
1 to 63
1
1
81
to
BF
1
0
1
1
1
0
to
1
1
1
0
0
0
0
0
0
C0
500 kBaud
1 = standard or
reprogrammed
1
1
0
0
0
0
1
1 to 62
1
1
1
1
1
0
C1
to
FE
500 kBaud
1
0
to
1
1
1
1
1
1
1
1
1
FF
250 kBaud
Monitoring mode/
programming mode
1 = firm
PROFIBUS DP
B7 B6 B5 B4 B3 B2 B1 B0
HEX
0
0
0
0
0
0
0
0
0
0
0
0
0
0
to
1
0
1
1
0
0
0
1
0
80
to
FE
1
1
FF
0
1
1
1
1
1
0
0
0
0
1
1
1
1
1
0
to
1
1
1
1
1
1
1
01
to
7E
1 to 126
with parameter channel
1 to 126
without parameter channel
Monitoring operation address 125
B0
2 1
ON
1 2 3 4 5 6 7 8
B7
B0
1 2 3 4 5 6 7 8
2 1
ON
B7
ON
125 = standard or reprogrammed
setting
ON
1) Factory
00
Address range
1)
With PROFIBUS:
Activation of the bus termination by means of the two lower
switches:
Figure on the left: Bus termination not activated
Figure on the right:Bus termination activated
(both switches to “ON“)
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
7/20
Integrated electronics (IFB-P)
Block circuit diagram
X2
PROFIBUS
alternative
PROFIBUS
controller
X3
X3
CAN bus
X2
Command value of
valve spool position D
U/I
Reference potential
U
E
Actual valve
spool position
Reference potential
A
D
CAN controller
F
C
U/I
U
Controller
PWM
D
Microcontroller
EEPROM
PWM
A
Output stage
OFF
Actual
position
value
Output stage B
U
I
PID
U
I
Solenoid b
Output stage A
Solenoid a
Flash
Oscillator
demodulator
=
~
Cable break
24V signal
supply
A
GND
B
Protective earth
conductor
PE
Inductive
position
transcuder
+Ui
–Ui
GND
DC
DC
1)
Command value: A positive command value of 0 to +10 V (or 12 to 20 mA) at D and reference potential at E corresponds to a
flow from P to A and B to T.
A negative command value of 0 to –10 V (or 12 to 4 mA) at D and reference potential at E corresponds to a
flow from P to B and A to T.
Actual value:
Positive actual value of 0 to +10 V (or 12 to 20 mA) at F and reference potential at C corresponds to a
flow from P to A and B to T.
Connection cable: Recommendation:
– Up to 25 m cable length, type LiYCY 7x0.75 mm2
– Up to 50 m cable length, type LiYCY 7x1.00 mm2
For outer dimensions, see sketch of mating connector
1) The
protective earth conductor (PE) is connected to the heat sink and the valve body
8/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Characteristic curves of size 6 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)
Transfer function with stepped electrical input signals
4/3 valve variant, spool symbol “V“
Signal change in % →
100
0 – 100 – 0
90
Stroke in % →
80
0 – 75 – 0
70
60
0 – 50 – 0
50
40
30
0 – 25 – 0
20
10
10
20
30
40
Time in ms →
0
10
20
30
Amplitude ratio in dB →
Frequency response characteristic curves – spool symbol V
5
–315
0
–3
–5
–270
–10
–180
–15
–135
–20
–90
–25
–45
–30
–225
30
10
20
Frequency in Hz →
1
50
100
Phase angle in ° →
0
Signal ±10 %
Signal ±25 %
Signal ±100 %
0
200
Flow/load function with max. valve aperture – spool symbol V
200
100
80
Permissible
max. flow
32
Flow in l/min →
16
08
10
P → A / B → T
or
1
10
P → B / A → T
20
50
100
Valve pressure differential in bar →
200
300
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
Characteristic curves of size 6 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)
Pressure/signal characteristic curve, pS = 100 bar – spool symbol V
100
80
60
20
pS
DpL
in % →
40
–5
–3
–1
1
3
5
←
– 20
– 40
– 60
– 80
– 100
UE
←
UEN
in % →
Leakage flow with central spool position  – spool symbol V
Leakage flow in l/min →
2
1
0
50
100
150
200 210 250
Operating pressure in bar →
300 315
9/20
10/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Characteristic curves of size 6 (measured with HLP46, ϑoil = 40 °C ±5 °C, p = 100 bar)
8 l/min nominal flow at 10 bar valve pressure differential
Flow in l/min →
30
5
P → A / B → T
or
20
4
3
2
1
P → B / A → T
10
0
10
15 20
20
30
30
40
40
50
50
60
70
80
90
2
Dp = 20 bar constant
3
Dp = 30 bar constant
4
Dp = 50 bar constant
5
Dp = 100 bar constant
100 V-spool
5
P → A / B → T
or
P → B / A → T
Flow in l/min →
Dp = 10 bar constant
100 E- and W-spool
60
70
80
90
Command value in % →
16 l/min nominal flow at 10 bar valve pressure differential
60
50
1
4
40
3
30
1
Dp = 10 bar constant
2
Dp = 20 bar constant
3
Dp = 30 bar constant
4
Dp = 50 bar constant
5
Dp = 100 bar constant
2
20
1
10
0
10
15 20
20
30
30
40
40
50
50
60
60
70
80
90
70
80
90
100
Command value in % →
100
V-spool
E- and W-spool
Flow in l/min →
32 l/min nominal flow at 10 bar valve pressure differential
120
110
P → A / B → T
100
or
90
P → B / A → T
5
Permissible max. flow
Note:
80
4
70
60
3
50
40
30
20
Observe flow/load function
on page 8!
1
Dp = 10 bar constant
2
Dp = 20 bar constant
2
3
Dp = 30 bar constant
1
4
Dp = 50 bar constant
5
Dp = 100 bar constant
10
0
15 20
20
10
30
30
40
40
50
50
60
70
60
70
80
90
Command value in % →
80
90
100
100 V-spool
E- and W-spool
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
11/20
Characteristic curves of size 10 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)
Transfer function with stepped electrical input signals
4/3 valve variant, spool symbol V
Signal change in % →
0 – 100 – 0
75
0 – 75 – 0
50
0 – 50 – 0
25
0 – 25 – 0
60
0
Time in ms →
Frequency response characteristic curves – spool symbol V
Amplitude ratio in dB →
0
20
40
20
40
60
5
–315
0
–270
–3
–5
–225
–10
–180
–15
–135
–20
–90
–25
–45
–30
1
10
20
30
Frequency in Hz →
50
100
Phase angle in ° →
Stroke in % →
100
Signal ±10 %
Signal ±25 %
0
200
Signal ±100 %
Flow load function at max. valve aperture – spool symbol V
400
75
Flow in l/min →
180
Permissible
max. flow
50
100
25
50
25
P → A / B → T
or
10
P → B / A → T
10
20
50
100
Valve pressure differential in bar →
200
300
12/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Characteristic curves of size 10 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)
Pressure/signal characteristic curve, pS = 100 bar – spool symbol V
100
80
60
pS
20
–5
–3
–1
1
3
5
– 20
←
DpL
in % →
40
– 40
– 60
– 80
– 100
←
UE
UEN
in % →
Leakage flow with central spool position – spool symbol V
Leakage flow in l/min →
2
1
0
50
100
150
200 210 250
Operating pressure in bar →
300 315
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
Characteristic curves of size10 (measured with HLP46, ϑoil = 40 °C ±5 °C, p = 100 bar)
25 l/min nominal flow at 10 bar valve pressure differential
80
70
Flow in l/min →
60
5
P → A / B → T
or
P → B / A → T
4
50
3
40
1
Dp = 10 bar constant
2
Dp = 20 bar constant
3
Dp = 30 bar constant
4
Dp = 50 bar constant
5
Dp = 100 bar constant
2
30
1
20
10
0
10
20
30
40
10
20
30
40
50
50
60
70
80
90
60
70
80
90
Command value in % →
50 l/min nominal flow at 10 bar valve pressure differential
100
150
125
P → A / B → T
100
P → B / A → T
4
3
75
V-spool
E- and W-spool
5
or
Flow in l/min →
100
1
Dp = 10 bar constant
2
Dp = 20 bar constant
3
Dp = 30 bar constant
4
Dp = 50 bar constant
5
Dp = 100 bar constant
2
50
1
25
0
10
10
20
30
40
20
30
40
50
50
60
70
80
90
60
70
80
90
Command value in % →
100
75 l/min nominal flow at 10 bar valve pressure differential
300
Flow in l/min →
180
P → A / B → T
225
or
200
P → B / A → T
E- and W-spool
Observe flow/load function
on page 11!
4
175
150
125
100
3
1
Dp = 10 bar constant
2
2
Dp = 20 bar constant
3
Dp = 30 bar constant
4
Dp = 50 bar constant
5
Dp = 100 bar constant
1
75
50
25
0
10
V-spool
5 Permissible max. flow
Note:
275
250
100
10
20
30
40
50
60
70
20
30
40
50
60
70
80
Command value in % →
V-spool
80
90
100
90
100
E- and W-spool
13/20
14/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Unit dimensions of size 6 (dimensions in mm)
7
8
118,3
6
23
47
"b"
42
"a"
13,6
55,6
45
139,4
18
123,8
152,4
5
2
4
1
3
8,5
Required surface quality
of valve mounting face
48
0,01/100mm
9
20
Rzmax 4
F1
F2
T
A
B
P
F4
G
F3
76
1 Valve housing
2 Proportional solenoid “a“ with inductive position transducer
3 Proportional solenoid “b“
4 R-ring 9.81 x 1.5 x 1.78 (ports A, B, P, T)
5 Space required to remove mating connector
6 Integrated digital electronics
7 Mating connector to DIN EN 175201-804, separate
order, see page 17
8 Nameplate
9 Machined valve mounting face, porting pattern to
ISO 4401-03-02-0-05
Deviating from standard:
– Ports A, B, P, T Ø8 mm
– Bore G is not required, because valve is not provided with a pin
Subplates to data sheet RE 45052
(separate order)
G 341/01
G 342/01
G 502/01
(G1/4)
(G3/8)
(G1/2)
Valve mounting screws (separate order)
The following valve mounting screws are recommended:
– 4 hexagon socket head cap screws
ISO 4762 - M5 x 50 - 10.9-flZn-240h-L
(Friction coefficient μtotal = 0.09 to 0.14)
Tightening torque MT = 7 Nm ±10 %,
Material no. R913000064 (separate order)
or
– 4 hexagon socket head cap screws ISO 4762 - M5 x 50 - 10.9
(Friction coefficient μtotal = 0.12 to 0.17)
Tightening torque MT = 8.9 Nm ±10 %
The tightening torques given are guidelines when screws of the
specified friction coefficient and a torque wrench are used (tolerance ±10 %).
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
15/20
Unit dimensions of size10 (dimensions in mm)
5
7
6
8
185,2
18
72,5
“b”
30
40
“a”
19,1
73
69,3
185,9
180,3
2
4
1
9
3
23
13
Required surface quality
of valve mounting face
F1 P
0,01/100mm
72
Rzmax 4
F2
A
B
T
T1
F4
F3
94
1 Valve housing
2 Proportional solenoid “a“ with inductive position transducer
3 Proportional solenoid “b“
4 R-ring 13.0 x 1.6 x 2.0 (ports A, B, P, T, T1)
5 Space required to remove mating connector
6 Integrated digital electronics
7 Mating connector to DIN EN 175201-804, separate
order, see page 17
8 Nameplate
9 Machined valve mounting face, porting pattern to
ISO 4401-05-04-0-05
Deviating from standard:
– Port T1 is provided additionally
Subplates to data sheet RE 45054
(separate order)
G 66/01
G 67/01
G 534/01
(G3/8)
(G1/2)
(G3/4)
Valve mounting screws (separate order)
The following valve mounting screws are recommended:
– 4 hexagon socket head cap screws
ISO 4762 - M6 x 40 - 10.9-flZn-240h-L
(Friction coefficient μtotal = 0.09 to 0.14)
Tghtening torque MT = 12.5 Nm ±10 %,
Material no. R913000058 (separate order) or
–4 hexagon socket head cap screws ISO 4762 - M6 x 40 - 10.9
(Friction coefficient μtotal = 0,12 to 0,17)
Tightening torque MT = 15.5 Nm ±10 %
The tightening torques given are guidelines when screws of the
specified friction coefficient and a torque wrench are used (tolerance ±10 %).
16/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Accessories (not included in the scope of supply)
The following is required for parameterization with a PC: CANopen
PROFIBUS DP
1
Interface converter (USB)
VT-ZKO-USB/P-1-1X/V0/0
Material no. R901071962
2
Operator tool
3
Connection cable, 3 m
VT-ZKO-USB/CA-1-1X/V0/0
Material no. R901071963
WIN-PED 6
Download at www.boschrexroth.de/IAC
D-Sub / M12, coding A
Material no. R900751271
D-Sub / M12, coding B
Material no. R901078053
2
3
1
RE 29048/04.08
Hydraulics Bosch Rexroth AG
4WREF
Accessories (not included in the scope of supply)
Connection X1
Mating connector to DIN EN 175201-804
Separate order stating Material no. R900021267 (plastic variant)
Angled form – separate order stating Material no. R900217845
For pinout, see also block circuit diagram on page 7
91
A
Ø27
B
Ø6,5…11
C
Mating connector to DIN EN 175201-804
85
Ø8…Ø13,5
Separate order stating Material no. R900223890 (metal variant)
D
F
E
17/20
18/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Accessories (not included in the scope of supply)
CAN bus (A-coding)
Description
Detail, dimensions
Pin pattern, order information
X2
4
5
2
Ø19,6
Straight mating connector,
metal variant
3
ca. 56
Circular plug-in connector,
to be wired by customer,
5-pin, M12
1
Mat. no: R901076910
(cable diameter 6 to 8 mm)
X3
ca. 61
Circular plug-in connector,
to be wired by customer,
5-pin, M12
2
5
4
Ø19,6
Straight plug-in connector,
metal variant
3
1
Mat. no: R901076906
(cable diameter 6 to 8 mm)
M12 cap
Dust protector
(for pins only)
Mat. no.: R901075564
PROFIBUS (B-coding)
Description
Detail, dimensions
X2
Straight plug-in connector,
metal variant
ca. 61
5
M12 protective cap
(for mating connector
only)
3
ca. 56
4
3
Ø19,6
Straight mating connector,
metal variant
2
Mat. no.: R901075545
(cable diameter 6 to 8 mm)
X3
Circular plug-in connector,
to be wired by customer,
5-pin, M12
4
1
Ø19,6
Circular plug-in connector,
to be wired by customer,
5-pin, M12
Pin pattern, order information
5
2
1
Mat. no.: R901075550
(cable diameter 6 to 8 mm)
Mat. no.: R901075563
RE 29048/04.08
4WREF
Hydraulics Bosch Rexroth AG
19/20
Engineering / maintenance notes / supplementary information
Product documentation for IFB-P
Technical data sheet for 4WREF, RE 29048 (this data sheet)
Operating manual RE 29015-B
CAN bus protocol description RE 29015-01-Z
PROFIBUS protocol description RE 29015-02-Z
General information on maintenance and commissioning of hydraulic components
RE 07800 / RE 07900
Commissioning software WIN-PED and documentation on the Internet: www.boschrexroth.com/IAC
Maintenance notes:
–The devices are tested in the factory and shipped with default settings.
–Only complete components can be repaired. The repaired devices will again be shipped with default settings.
User settings are not retained or reloaded. The operator must reload the relevant user parameters.
Notes:
–Only apply the supply voltage for the valve if demanded by the functional sequence of the machine.
–Electrical signals brought out via control electronics (e.g. signal “ready“) must not be used for switching safety-relevant machine
functions! (See also European standard “Safety requirements for fluid power systems and components – hydraulics“, EN 982.)
–If electromagnetic interference is to be expected, suitable measures must be taken to safeguard the function (depending on the
application, e.g. shield, filtration)!
–For further notes, see operating manual and WIN-PED 6 online help.
20/20
Bosch Rexroth AG Hydraulics
4WREF
RE 29048/04.08
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
©This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application
can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process of
wear and aging.
4/3 proportional directional valve,
direct operated, with pQ functionality
and field bus interface (IAC-P)
RE 29050/01.08
Replaces: 07.05
1/28
Type 4WREQ
Sizes 6 and 10
Component series 2X
Maximum operating pressure 315 bar
Maximum flow 180 l/min
HAD 7099/03
Table of contents
Features
Content
Page
Features
1
Ordering code
2
Symbols
2
Standard types
Structure, function, section
Technical data
Closed-loop control electronics,
identification and adjustment elements
Electrical connections and pinout
3
3 to 5
6 and 7
–Direct operated proportional directional valve with integrated
digital control electronics for the closed-loop control of pressure, force and flow (Integrated Axis Controller IAC-P)
– Completely matched unit consisting of valve, pressure
sensor(s) (optional), digital closed-loop control electronics and
field bus interface
–Actuation by proportional solenoid with central thread and
detachable coil
–Position-controlled valve spool
8
8 and 9
–Integrated pressure sensor plate (optional)
–For subplate mounting: Porting pattern to ISO 4401
Settings for CANopen and PROFIBUS-DP
10
–Analog interfaces for command and actual values
Block circuit diagram
11
Characteristic curves
12 to 19
–Version for CAN bus with CANopen protocol DS 408 or
PROFIBUS-DP V0/V1
Unit dimensions
20 to 23
Accessories
24 to 26
Engineering / maintenance notes / supplementary information 27
–Fast commissioning by means of PC and
commissioning software WIN-PED 6
2/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Ordering code
4WRE
Q
2X
V
24
*
With integrated digital electronics and pQ functionality = Q
=6
= 10
Size 6
Size 10
Spool symbols
a
Further details
in clear text
0
A
b
Sensor interface for external
pressure sensor 4)
2 =
4 to 20 mA
3 =
0 to 10 V
4 =
0 to 5 V
9 =
0.5 to 5 V
0 =
Without external
sensor interface
B
a 0 b
P
T
= Q5=V
Nominal flow 1)
Size 6
8 l/min
16 l/min
32 l/min
Size 10
25 l/min
50 l/min
75 l/min
= 08
= 16
= 32
Supply voltage
24 VDC
24 =
= 25
= 50
= 75
Position of pressure sensors
External sensor
Internal sensor in channel
A
B
A+B
P+A+B
0 =
FKM - rectangular rings suitable for mineral oils
(HL, HLP) to DIN 51524
A =
B =
C =
F =
=V
Pressure rating with internal sensors
2)
100 bar
2)
160 bar
2)
250 bar
3)
400 bar
External sensor
Application
=4
=5
=8
=B
=0
1) See
flow characteristic curves starting on page 12.
2) The
selected pressure rating limits the max. valve pressure.
4)
Bus interface
CAN bus DS 408
PROFIBUS-DP V0/V1
C =
P =
Component series 20 to 29
= 2X
(20 to 29: unchanged installation and connection dimensions)
3) Attention:
Electronics interface 5)
±10 VDC
4 to 20 mA
A6 =
F6 =
Maximum valve pressure 315 bar
When internal pressure sensors are used, no external pressure sensor may be connected.
5)
Ordering code
Q control
F
p control only in A
A
p control only in B
B
p control in A + B or ∆p control
C
With command value input “A6“ only sensor interfaces “3“,
“4“ or “9“ are possible.
With command value input “F6“ only sensor interface “2“ is
possible.
Symbols
Type 4WREQ.Q5-...
Type 4WREQ.V...
P
G
A
B
P
T
a
P
G
b
A
B
P
T
a
b
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
3/28
Standard types
Size 6
Size 10
Type
Material no.
Type
Material no.
4WREQ 6 Q5-08-2X/V8F-24CA60
R901078399
4WREQ1 0 Q5-25-2X/V8F-24CA60
R901054628
4WREQ 6 Q5-16-2X/V8F-24CA60
R901054623
4WREQ 10 Q5-50-2X/V8F-24CA60
R901054633
4WREQ 6 Q5-32-2X/V8F-24CA60
R901054625
4WREQ 10 Q5-25-2X/VBF-24CA60
R901078407
4WREQ 6 Q5-08-2X/VBF-24CA60
R901078402
4WREQ 10 Q5-50-2X/VBF-24CA60
R901078409
4WREQ 6 Q5-16-2X/VBF-24CA60
R901078403
4WREQ 10 Q5-75-2X/V8F-24PA60
R901188093
4WREQ 6 Q5-32-2X/VBF-24CA60
R901078404
4WREQ 6 Q5-08-2X/V5C-24PF60
R901136691
4WREQ 6 Q5-16-2X/V5F-24PA60
R901164003
4WREQ 6 Q5-32-2X/V5A-24PF60
R901174304
4WREQ 6 V08-2X/V5F-24PF60
R901166349
Structure, function, section (valve with integrated sensors)
Structure
The valve basically consists of:
–Housing (1) and pressure sensor plate (12) with connection
face
­­–Position transducer (7)
–Control spool (2) with compression springs (3 and 4) and
spring plates (8 and 9)
–Integrated digital closed-loop control electronics IAC-P (11)
­–Integrated pressure sensors (10)
­­–Coils (5 and 6) and pole tubes (14 and 15) with central
thread
Continued on page 4
11
X1
X2
X3
P
7
5
14
3
10
8
A
B
2
T
9
12
1
4
15
Note:
Draining of the tank line must be prevented. If the installation situation allows, install a suitable pre-load valve.
6
4/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Structure, function, section (valve with integrated sensors)
Continued from page 3
Functional description
– When solenoids (5 and 6) are de-energized, control spool
(2) is brought by compression springs (3 and 4) between
spring plates (8 and 9) to the central position (if V-spool is
used, without spring plates). With V-spools, the mechanical
zero position is not identical with the hydraulic zero position.
–Depending on the valve type, the following functions can be
performed (in some cases, combinations are possible):
• Open-loop flow control (Q)
• Closed-loop flow control (Q)
• Closed-loop pressure control in A and/or B (p)
• Closed-loop force control (p)
• Alternating closed-loop control of p/Q
–The command values can be fed forward alternatively via an
analog interface (X1) or via the field bus interface (X2, X3).
The following additional functions are available:
–Ramp generator
–Internal command value profile
–Enable function analog / digital
– Fault output 24 V
PC program WIN-PED 6
For performing engineering work and parameterizing IAC-P
valves, the user can utilize the commissioning software WINPED 6.
- Parameterization
- Diagnosis
- Comfortable data administration on a PC
System requirements
–The actual value signals are made available via an analog
interface (X1) and can be read out additionally via the field
bus (X2, X3).
–IBM PC or compatible system
–The controller parameters are adjusted via the field bus
–150 MB free hard disk space
–For safety reasons, separate supply voltage for bus/controller and power part (output stage) The digital integrated control electronics allows the following
faults to be detected:
–Cable break of pressure sensor (10)
–Undervoltage
–Cable break of position transducer (7)
–Communication error
–Watchdog
–Cable break of command value inputs (with current interface
only)
–Windows 2000 or Windows XP
–RAM (recommendation 256 MB)
Note
–The program “WIN-PED 6“ is not included in the scope of
supply. It can be downloaded free of charge on the Internet!
(See page 24)
Structure, function, section (valve for external sensor)
Structure
The valve basically consists of:
–Housing (1) with mounting face
–Control spool (2) with compression springs (3 and 4) and
spring plates (8 and 9)
­­–Coils (5 and 6) and pole tubes (10 and 11) with central
thread
­­–Position transducer (7)
–Integrated digital closed-loop control electronics IAC-P (12)
–Connection (X4) for an external pressure sensor (14)
Continued on page 5
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
5/28
Structure, function, section (valve for external sensor)
Continued from page 4
Functional description
– When solenoids (5 and 6) are de-energized, control spool
(2) is brought by compression springs (3 and 4) between
spring plates (8 and 9) to the central position (if V-spool is
used, without spring plates). With V-spool, the mechanical
zero position is not identical with the hydraulic zero position.
–Functions:
• Open-loop flow control (Q)
–Watchdog
–Cable break of command value inputs (with current interface
only)
The following additional functions are available:
–Ramp generator
–Internal command value profile
–Enable function analog / digital
–Fault output 24 V
• Closed-loop pressure control (p)
• Alternating closed-loop control of p/Q
PC program WIN-PED 6
–The command values can be fed forward alternatively via an
analog interface (X1) or via the field bus interface (X2, X3).
For performing engineering work and parameterizing the IAC-P
valves, the user can utilize the commissioning software WINPED 6.
–The actual value signals are made available via an analog
interface (X1) and can be read out additionally via the field
bus (X2, X3).
- Parameterization
- Diagnosis
–The controller parameters are adjusted via the field bus
–For safety reasons, separate supply voltage for bus/controller and power part (output stage)
The digital integrated control electronics allow the following
faults to be detected:
–Cable break of pressure sensor supply cable
(depending on pressure sensor interface)
–Undervoltage
–Cable break of position transducer (7)
–Communication error
- Comfortable data administration on a PC
System requirements
–IBM PC or compatible system
–Windows 2000 or Windows XP
–RAM (recommendation: 256 MB)
–150 MB free hard disk space
Note
–The program “WIN-PED 6“ is not included in the scope of
supply. It can be downloaded free of charge on the Internet!
(See page 24)
12
X1
X2
X3
X4
14
7
5
10
3
8
1
2
9
4
11
6
Note:
Draining of the tank line must be prevented. If the installation situation allows, install a suitable pre-load valve.
6/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Technical data (for applications outside these parameters, please consult us!)
General
Size 6
Installation position
Size10
Optionally, preferably horizontal
Storage temperature range
°C –20 … +80
Ambient temperature range
°C –20 … +50
Weight with sandwich plate (3 sensors)
kg
3.6
8.5
Weight without sandwich plate
kg
2.4
6.5
8
25
Hydraulic (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Operating pressure 1)
Ports P, A, B with sensor
Port T
with sensor
100 bar
bar up to 100
160 bar
bar up to 160
250 bar
bar up to 250
400 bar
bar up to 315
100 bar
bar up to 100
160 bar
bar up to 160
250 bar
bar up to 210
400 bar
bar up to 210
Nominal flow qV nom at ∆p = 10 bar
See flow characteristic curves from page 18 on
l/min
Max. permissible flow
l/min
Hydraulic fluid
16
50
32
75
80
180
Mineral oil (HL, HLP) to DIN 51524,
further hydraulic fluids on request
Hydraulic fluid temperature range
°C –20 … +70, preferably +40 … +50
mm2/s
Viscosity range
Permissible max. degree of contamination of the hydraulic fluid cleanliness class to ISO 4406 (c)
20 … 380, preferably 30 … 46
Class 20/18/15 2)
Hysteresis (closed-loop position control - valve spool)
% ≤ 0.1
Range of inversion (closed-loop position control - valve spool)
% ≤ 0.05
Response sensitivity (closed-loop position control - valve spool)
% ≤ 0.05
Valve spool zero point drift upon change of hydraulic fluid
temperature and operating pressure
%/10 K < 0.15
%/100 bar < 0.1
Electrical
Supply voltage
Nominal voltage
VDC 24
Lower limit value
VDC 19.4
VDC 35
Upper limit value
Max. permissible residual ripple content
Current consumption
I max
Command and
actual value signals
Voltage "A6"
A 2
Impulse current
Current "F6"
A 3
UQ
V ±10
Up
V 0…10
IQ and Ip
mA 4 … 20
Converter resolution (command/actual value signals)
Duty cycle
3)
Max. coil temperature
Vss 2
Bit 10
% 100
4)
Type of protection of valve to EN 60529:1991+A1:2000
°C up to 150
IP 65 with plug-in connectors mounted and locked
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
7/28
Technical data (for applications outside these parameters, please consult us!)
Sensorics
Sizes 6 and 10
Measuring range
pN
bar
100
160
250
400
Overload safety
pmax
bar
200
320
500
800
Burst pressure
p
bar
400
640
1000
1600
Calibration error
Zero point
< 0.25 % of final value
Final value
­­< 0.5 %
Temperature coefficient within the nominal temperature range
Highest TC of zero point
< 0.2 % / 10 K
Highest TC of range
­­< 0.2 % / 10 K
Characteristic curve deviation
­­< 0.2 %
Hysteresis
­­< 0.1 %
Repeatability
­­< 0.05 %
Long-term drift (1 year) under reference conditions
­­< 0.2 %
With an external pressure sensor, the accuracy of the closedloop pressure control depends on the accuracy class of the
sensor used.
1) Operating
pressure, due to valve and sensor
2) The
cleanliness classes specified for components must be
adhered to in hydraulic systems. Effective filtration prevents
malfunction and, at the same time, prolongs the service life
of components. For the selection of filters, see data sheets
RE 50070, RE 50076 and RE 50081.
3) Apply
supply voltage for the valve only when required for the
functional sequence of the machine.
4) Due
to the surface temperatures of solenoid coils, observe
European standards ISO 13732-1 and EN 982!
Note!
For details regarding environment simulation tests in the fields
of EMC (electromagnetic compatibility), climate and mechanical stress, see RE 29050-U (declaration on environmental
compatibility).
8/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Closed-loop control electronics (IAC-P), identification and adjustment elements
Rexroth
1: + 24V DC (UB)
2: 0V (UB)
3: enable input 24V DC
4: command value (Q) 1)
5: reference analog
1)
6: actual value (Q)
7: command value (p) 2)
2)
8: actual value (p)
9: control supply +24V
10: control supply 0V
11: error output 24V DC
PE: earth conductor
1)
±10V 2) 0... 10V
1
1 Material number
P
A
G
B
)(
∗R900975074∗
0000000 00
2
P
)(
4WREQ6....
0000
A001
3
T
4
5
6
2 Production order number
3 Date of production
4 Serial number
5 Type designation, e.g. 4WREQ…-2X/…
6 DIL switch for address and baud rate setting (position
B0 on the right), see page 10
Closed-loop control electronics (IAC-P), electrical connections and pinout
Plug-in connector pinout X1, 11-pin + PE to DIN EN 175201-804
Pin
No. or
litz wire
color 1)
1
1
2
2
3
white
4
yellow
5
green
6
violet
7
pink
8
red
Pinout of interface A6
Pinout of interface F6
24 VDC (u(t) = 19.4 V … 35 V), Imax = 1.7 A (for output stage)
0 V
load zero, reference for pins 1 and 9
Enable input 9 ... 35 V
±10 V command value Q
Ri > 50 kΩ
enable ON
Ri = 100 Ω
4...20 mA command value Q
Reference for command values Q and P
± 10 V actual value Q
(limit load 5 mA)
0 … 10 V command value P Ri > 50 kΩ
0 … 10 V actual value P
(limit load 5 mA)
4...20 mA actual value Q
(load resistance max. 300 Ω)
Ri = 100 Ω
4...20 mA command value P
4...20 mA actual value P
(load resistance max. 300 Ω)
9
brown
Control voltage, level like pin 1, Imax  = 0.3 A (for signal part and bus)
10
black
0V reference potential for pins 3, 6, 8 and 11 (connected to pin 2 within the valve)
11
blue
Fault output 24 V (19.4 V … 35 V), 200 mA max. load
PE
green-yellow
Connected to heat sink and valve housing
Connect shield to PE only on the supply side!
X1
1)
Litz wire color of connection cable for mating connector
with cable set (see Accessories)
4
3
10
9
5
6
11
7
2
1
8
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
9/28
Closed-loop control electronics (IAC-P), electrical connections and pinout
X2
3
Connector plug pinout for CAN bus “X2“/”X3“ (coding A),
M12, 5-pin, male/female
Pin
Assignment
1
n. c.
2
n. c.
3
CAN_GND
4
CAN_H
5
CAN_L
Baud rate
2
kbit/s
Bus address
5
4
20 to 1000
1 to 127
1
CAN-specfic settings:
The baud rate and identifier can be set via
the bus system or by means of the DIL
switches.
X3
3
4
5
2
1
X2
4
Connector plug pinout for PROFIBUS-DP, “X2“/”X3“ (coding B),
M12, 5-pin, male/female
Pin
Assignment
1
+5V
2
RxD/TxD-N (A-cable)
3
D GND
4
RxD/TxD-P (B-cable)
5
Shield
1
Baud rate
up to 12 MBaud
Bus address
1 to 126
5
3
2
Setting by means of DIL switches
X3
4
3
The +5-V voltage of the IAC-P is available for an external terminating resistor.
5
1
2
External pressure sensor connection “X4“ (coding A), M12, 5-pin, female
Pin
Assignment
voltage interface
Assignment
current interface
1
Supply 24 VDC
Supply 24 VDC
2
Signal (0...+5 V)
Signal (4...20 mA)
3
Zero 0 V (GND)
Zero 0 V (GND)
4
n. c.
n. c.
5
n. c.
n. c.
X4
Note:
We recommend that the shields be connected on both sides via the metal housings of the plug-in connectors.
The use of plug pins deteriorates the shield effect !
Internal shields are not required.
1
2
4
5
3
10/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Closed-loop control electronics (IAC-P), settings for CANopen and PROFIBUS-DP
CANopen
B7 B6 B5 B4 B3 B2 B1 B0
HEX
Baud rate: B7, B6
Address range: B5 to B0
0
0
0
0
0
0
0
0
00 1)
Standard 20 kBaud
or reprogrammed
1 = standard or
reprogrammed
0
0
0
0
0
0
1
20 kBaud
1 to 63
1
1
01
to
3F
0
0
1
1
1
0
to
1
0
1
0
0
0
0
0
0
40
125 kBaud
1 = standard or
reprogrammed
0
1
0
0
0
0
1
1 to 63
1
1
1
1
1
1
41
to
7F
125 kBaud
0
0
to
1
1
0
0
0
0
0
0
0
80
250 kBaud
1 = standard or
reprogrammed
1
0
0
0
0
0
1
1 to 63
0
1
1
1
1
1
81
to
BF
250 kBaud
1
0
to
1
1
1
0
0
0
0
0
0
C0
500 kBaud
1 = standard or
reprogrammed
1
1
0
0
0
0
1
1 to 62
1
1
1
1
1
0
C1
to
FE
500 kBaud
1
0
to
1
1
1
1
1
1
1
1
1
FF
250 kBaud
Monitoring mode/
programming mode
1 = fest
PROFIBUS-DP
B7 B6 B5 B4 B3 B2 B1 B0
HEX
0
0
0
0
0
0
0
0
0
0
0
0
0
0
to
1
0
1
1
0
0
0
1
0
80
to
FE
1
1
FF
0
1
1
1
1
1
0
0
0
0
1
1
1
1
1
0
to
1
1
1
1
1
1
1
01
to
7E
1 to 126
with parameter channel
1 to 126
without parameter channel
Monitoring mode address 125
B0
2 1
ON
1 2 3 4 5 6 7 8
B7
B0
1 2 3 4 5 6 7 8
2 1
ON
B7
ON
125 = Standard or reprogrammed
setting
ON
1) Factory
00
Address range
1)
Activation of the bus termination using the two lower switches
(with PROFIBUS-DP only):
Graphic on the left:
Graphic on the right:
Bus termination not activated
Bus termination activated
(both switches to “ON“)
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
11/28
Closed-loop control electronics (IAC-P), block circuit diagram
PROFIBUS-DP
PROFIBUS
controller
X2
Pressure sensor plate: Pressure in P
Pressure sensor plate: Pressure in A
Pressure sensor plate: Pressure in B
Pressure sensor plate: Pressure in T
X3
2)
X3
Alternatively
CAN bus
X1 4
Command value Q
Command value p
Actual value Q
Actual value p
7
6
8
Enable
3
Fault output
11
Reference for pins
4; 7
X4
I
I
I
I
A
U
A
U
24V signal supply
GND
Protective earth
conductor
9
2
D
A A A A
CAN
D D D D
controller
D
A
Controller
PWM
U
Output stage B
U
I
PWM
PID
Output
stage OFF
D
Microcontroller
5
1
D
PWM
U
Reference for pins
10
3; 6; 8; 11
24V load supply
External pressure
X2
EEPROM
A
Act. position value
Output stage A
U
I
Oscillator
demodulator
=
Flash
b
a
Inductive
position
transducer
~
Cable break
GND
Output stage supply
+Ui
–Ui
GND
DC
DC
PE
1)
Command value:
A positive command value of 0 to +10 V (or 12 to 20 mA) at pin 4 and reference potential at pin 5
corresponds to a flow from P → A and B → T.
A negative command value of 0 to –10 V (or 12 to 4 mA) at pin 4 and reference potential at pin 5 causes a
flow from P → B and A → T.
Actual value:
A positive actual value of 0 to +10 V (or 12 to 20 mA) at pin 6 and reference potential at pin 10 corresponds to a flow from P → A and B → T.
A negative actual value of 0 to -10V (or 12 to 4 mA) at pin 6 and reference potential at pin 10 corresponds to a flow from P → B and A → T.
Connection cable: Recommendation:
– up to 25 m cable length for pins 1; 2 and PE: 0.75 mm2, otherwise 0.25 mm2
– up to 50 m cable length for pins 1; 2 and PE: 1.00 mm2
For outer diameter, see mating connector sketch:
1) The
protective conductor (PE) is connected to the heat sink and the valve housing
2)Pressure
transducers in P, A, B and T according to the ordering code or external pressure sensor via the 5-pin M12 mating connector X4
12/28
Bosch Rexroth AG Hydraulics
4WREQ
Characteristic curves size 6 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Pressure/signal characteristic curve (Q5 spool), ps = 100 bar
Tolerance range of the mechanical zero position
(-6 to +6%)
100
80
60
20
–30 –24
–18
–12
pS
0
12
18
24
30
–20
←
∆pL
in %→
40
–40
–60
–80
–100
←
UE
UEN
in % →
Pressure/signal characteristic curve (V spool), ps  = 100 bar
100
80
60
∆pL
20
–5
–3
–1
1
– 20
←
pS
in %→
40
– 40
– 60
– 80
– 100
←
UE
UEN
in % →
3
5
RE 29050/01.08
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
Characteristic curves size 6 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Flow, size 6 with Q5 spool
Tolerance range of mechanical zero position
100
B→T
A→T
Flow in % →
80
60
P→A
P→B
40
20
0
–100
–80
–60
–40
–20
0
20
40
60
80
100
70
80
90
100
Command value in % →
Flow, size 6 with V spool
100
90
80
Flow in % →
70
60
50
40
30
20
10
0
10
20
V08 spool
V16 spool
V32 spool
30
40
50
60
Command value in % →
13/28
14/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Characteristic curves size 6 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Flow/load function, size 6 with Q5 spool at max. valve aperture
200
Permissible
maximum flow
100
Flow in l/min →
80
32
50
P→A/B→T
16
or
P→B/A→T
08
10
5
10
50
20
100
200
300
Valve pressure differential in bar →
Flow/load function, size 6 with V spool at max. valve aperture
Permissible
maximum flow
200
80
100
32
Flow in l/min →
16
P→A/B→T
08
or
P→B/A→T
10
1
10
20
50
100
Valve pressure differential in bar →
200
300
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
15/28
Characteristic curves size 6 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Stroke in % →
Transient function, size 6
Signal change in %
100
0 - 100
75
0 - 75
50
0 - 50
25
0 - 25
0
0
10
20
30
Time in ms →
0
10
20
30
Frequency response, size 6 with Q5 spool, ps = 10 bar
– 360
10
0
–3
–5
– 270
–10
– 180
–15
– 90
–20
Phase angle in ° →
Amplitude ratio in dB →
5
–25
–30
1
5
10
Frequency in Hz →
50
100
200
Signal 50 ± 5 %
Signal 50 ± 12.5 %
Signal 50 ± 50 %
Frequency response, size 6 with V spool, ps = 10 bar
10
– 360
0
–3
–5
– 270
– 10
– 180
– 15
– 90
– 20
Phase angle in ° →
Amplitude ratio in dB →
5
– 25
– 30
1
5
10
Frequency in Hz →
50
100
200
0
Signal ± 10 %
Signal ± 25 %
Signal ± 1
00 %
16/28
Bosch Rexroth AG Hydraulics
4WREQ
Characteristic curves size 10 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Pressure/signal characteristic curve (Q5 spool), ps = 100 bar
Tolerance range of mechanical zero position
(-6 to +6 %)
100
80
20
–30
–24
–18
–12
0
←
∆pL
40
pS
in %→
60
12
18
24
30
–20
–40
–60
–80
–100
UE
←
in % →
UEN
Pressure/signal characteristic curve (V spool), ps  = 100 bar
100
80
60
∆pL
20
–5
–3
–1
1
– 20
←
pS
in %→
40
– 40
– 60
– 80
– 100
←
UE
UEN
in % →
3
5
RE 29050/01.08
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
Characteristic curves size 10 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Flow, size 10 with Q5 spool
Tolerance range of mechanical zero position
100
Flow in % →
B→T
A→T
80
60
40
P→A
P→B
20
0
–100
–80
–60
–40
–20
0
20
40
60
80
100
70
80
90
100
Command value in % →
Flow, size 10 with V spool
100
90
80
Flow in % →
70
60
50
40
30
20
10
0
10
20
30
40
50
60
Command value in % →
V25 spool
V50 spool
V75 spool
17/28
18/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Characteristic curves size 10 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Flow/load function, size 10 with Q5 spool at max. valve aperture
400
Permissible
maximum flow
180
Flow in l/min →
75
25
50
100
P→A/B→T
or
50
P→B/A→T
20
10
10
50
20
100
200
300
Valve pressure differential in bar →
Flow/load function, size 10 with V spool at max. valve aperture
400
Permissible
maximum flow
75
Flow in l/min →
180
50
100
P→A/B→T
or
25
50
P→B/A→T
20
10
10
20
50
100
Valve pressure differential in bar →
200
300
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
19/28
Characteristic curves size 10 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Stroke in % →
Transient function, size 10
Signal change in %
100
0 - 100
75
0 - 75
50
0 - 50
25
0 - 25
0
0
10
20
30
40
50
0
10
20
30
40
50
Time in ms →
Frequency response, size 10 with Q5 spool, ps = 10 bar
– 360
10
0
–3
–5
– 270
– 10
– 180
– 15
Phase angle in °
Amplitude ratio in dB →
5
– 90
– 20
– 25
– 30
1
5
10
50
100
Frequency in Hz →
200
0
Signal 50 ± 5 %
Signal 50 ± 12.5 %
Signal 50 ± 50 %
Frequency response, size 10 with V spool, ps = 10 bar
– 360
10
0
–3
–5
– 270
– 10
– 180
– 15
– 90
– 20
Phase angle in ° →
Amplitude ratio in dB →
5
– 25
– 30
1
5
10
Frequency in Hz →
50
100
200
0
Signal ± 10 %
Signal ± 25 %
Signal ± 1
00%
20/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Unit dimensions size 6 (dimensions in mm) Type 4WREQ with integrated pressure sensors
7
8
158,8
6
"a"
40,5
82,5
23
47
"b"
19,5
55,5
88,5
45
123,8
140
152,4
18
5
9
2
4
1
3
8,5
0,01/100
10
15
F1
1 Valve housing
47
Rzmax 4
Required surface quality of
valve mounting face
F2
T
A
B
P
F4
G
2 Proportional solenoid "a" with inductive position transducer
72
3 Proportional solenoid "b"
4 R-ring 9.81 x 1.5 x 1.78 (ports P, A, B, T)
5 Space required to remove mating connector
6 Integrated digital closed-loop control electronics
7 Mating connector to DIN EN 175201-804;
separate order, see page 25
8 Nameplate
9 Integrated pressure transducers
10 Machined valve mounting face,
porting pattern to ISO 4401-03-02-0-05
Deviating from standard:
–Ports P, A, B, T Ø8 mm
–Bore G is not required, since the valve is not provided
with a pin.
Subplates according to data sheet RE 45052 and valve
mounting screws must be ordered separately.
Subplates:
G341/01 (G1/4)
G342/01 (G3/8)
G502/01 (G1/2)
Valve mounting screws:
4 hexagon socket head cap screws
ISO 4762-M5x90-10.9-flZn-240h-L
(Friction coefficient μtotal : 0.09-0.14 to VDA 235-101)
tightening torque MT = 8.9 Nm ± 10 %
Material no. R913000222
F3
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
21/28
Unit dimensions size 6 (dimensions in mm) Type 4WREQ for external pressure sensor
7
8
118,3
6
23
47
"b"
42
"a"
13,6
55,6
45
139,4
152,4
5
2
4
1
3
8,5
18
123,8
Rzmax 4
F1
47
0,01/100
9
15
Required surface quality of
valve mounting face
F2
T
A
B
P
F4
G
72
1 Valve housing
2 Proportional solenoid "a" with inductive position transducer
3 Proportional solenoid "b"
4 R-ring 9.81 x 1.5 x 1.78 (ports P, A, B, T)
5 Space required to remove mating connector
6 Integrated digital closed-loop control electronics
7 Mating connector to DIN EN 175201-804;
separate order, see page 25
8 Nameplate
9 Machined valve mounting face,
porting pattern to ISO 4401-03-02-0-05
Deviating from standard:
–Ports P, A, B, T Ø8 mm
–Bore G is not required, since the valve is not provided
with a pin.
Subplates according to data sheet RE 45052 and valve
mounting screws must be ordered separately.
Subplates:
G341/01 (G1/4)
G342/01 (G3/8)
G502/01 (G1/2)
Valve mounting screws:
–4 hexagon socket head cap screws
ISO 4762-M5x50-10.9-flZn-240h-L
(Friction coefficient μtotal = 0.09 to 0.14)
tightening torque MT = 7 Nm ± 10 %,
Material no. R913000064
or
–4 hexagon socket head cap screws
ISO 4762-M5x50-10.9
(Friction coefficient μtotal = 0.12 to 0.17)
tightening torque MT = 8.9 Nm ± 10 %
F3
22/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Unit dimensions size 10 (dimensions in mm) Type 4WREQ with integrated pressure sensors
7
"a"
40,5
30
40
72,5
"b"
69,3
73
24
93
180,3
185,9
2
4
1
3
23
F1 P
A
72
0,01/100
Rzmax 4
9
13
8
B
T
Required surface quality of
valve mounting face
F2
T1
F4
F3
100
1 Valve housing
2 Proportional solenoid "a" with inductive position transducer
Subplates according to data sheet RE 45054 and valve
mounting screws must be ordered separately.
4 R-ring 13.0 x 1.6 x 2.0 (ports P, A, B, T1, T2)
Subplates:
5 Integrated digital closed-loop control electronics
Valve mounting screws:
6 Mating connector to DIN EN 175201-804;
separate order, see page 25
–4 hexagon socket head cap screws
ISO 4762-M6x80-10.9-flZn-240h-L
(Friction coefficient μtotal = 0.09 to 0.14)
tightening torque MT = 12.5 Nm ± 10 %,
Material no. R913000512 (separate order)
3 Proportional solenoid "b"
7 Nameplate
8 Integrated pressure transducers
9 Machined valve mounting face,
porting pattern to ISO 4401-05-04-0-05
G66/01 (G3/8)
G67/01 (G1/2)
G534/01 (G3/4)
or
–4 hexagon socket head cap screws
ISO 4762-M6x80-10.9
(Friction coefficient μtotal = 0.12 to 0.17)
tightening torque MT = 15.5 Nm ± 10 %
185,2
5
6
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
23/28
Unit dimensions size 10 (dimensions in mm) Type 4WREQ for external pressure sensor
5
7
144,7
6
"a"
30
40
72,5
"b"
19,1
73
69,3
185,9
180,3
2
4
1
3
8
13
20
0,01/100
F1 P
72
Rzmax 4
Required surface quality
of valve mounting face
F2
A
B
T
T1
F4
F3
94
1 Valve housing
2 Proportional solenoid "a" with inductive position transducer
Subplates according to data sheet RE 45054 and valve
mounting screws must be ordered separately.
4 R-ring 13.0 x 1.6 x 2.0 (ports A, B, P, T, T1)
Subplates:
5 Integrated digital closed-loop control electronics
Valve mounting screws:
6 Mating connector to DIN EN 175201-804;
separate order, see page 25
–4 hexagon socket head cap screws
ISO4762-M6x40-10.9-flZn-240h-L
(Friction coefficient μtotal = 0.09 to 0.14)
tightening torque MT = 12.5 Nm ± 10 %,
Material no. R913000058 (separate order)
3 Proportional solenoid "b"
7 Nameplate
8 Machined valve mounting face,
porting pattern to ISO 4401-05-04-0-05
G66/01 (G3/8)
G67/01 (G1/2)
G534/01 (G3/4)
or
– 4 hexagon socket head cap screws
ISO 4762-M6x40-10.9
(Friction coefficient μtotal = 0.12 to 0.17)
tightening torque MT = 15.5 Nm ± 10 %
24/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Accessories (not included in the scope of supply)
The following is required for parameterization by means of a PC:
CANopen
PROFIBUS-DP
1
VT-ZKO-USB/CA-1-1X/V0/0
VT-ZKO-USB/P-1-1X/V0/0
Mat. no. R901071963
Mat. no. R901071962
2
Interface converter (USB)
WIN-PED 6
Commissioning software
Download über www.boschrexroth.de\IAC
3
Connection cable, 3 m
D-Sub / M12, coding A
D-Sub / M12, coding B
Mat. no. R900751271
Mat. no. R901078053
2
3
1
Hydraulics Bosch Rexroth AG
RE 29050/01.08 4WREQ
25/28
Accessories, connection X1 (not included in the scope of supply)
Mating connector für X1
Mating connector to DIN EN 175201 - 804
(11-pin + PE), plastic variant
7
4
Material no. R900032356
• Mating connector with cable set 2 x 20 m 12-pin
Material no. R900860399
2
9
8
• Mating connector with cable set 2 x 5 m 12-pin
3
10
11
Material no. R900884671
33
5
6
• Mating connector without cable (kit)
1
90
Accessories, sensor connection (not included in the scope of supply)
Description
Detail, dimensions
X4 (analog sensor)
ca. 61
3
Ø19,6
Plug-in connector,
5-pin, M12, male,
A coding,
straight connector, metal variant
Pin pattern, order information
2
4
5
1
Mat. no.: R901075542
(Cable diameter 4 to 6 mm)
26/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Accessories, CAN bus (A coding) (not included in the scope of supply)
Description
Detail, dimensions
X2
Straight mating
connector, metal
variant.
ca. 56
1
5
3
ca. 61
3
2
5
4
Ø19,6
Straight plug-in
connector, metal
variant.
4
Mat. no.: R901076910
(Cable diameter 6 to 8 mm)
X3
Circular plug-in
connector,
to be wired by
user, 5-pin, M12
2
Ø19,6
Circular plug-in
connector,
to be wired by
user, 5-pin, M12
Pin pattern, order information
1
Mat. no.: R901076906
(Cable diameter 6 to 8 mm)
M12 cap
Dust protector for
plugs only
Mat. no.: R901075564
Accessories, PROFIBUS (B coding) (not included in the scope of supply)
Description
Detail, dimensions
X2
Straight plug-in
connector, metal
variant.
ca. 61
M12 protective
cap (for mating
connector only)
3
2
ca. 56
4
3
Ø19,6
Straight mating
connector, metal
variant.
5
Mat. no.: R901075545
(Cable diameter 6 to 8 mm)
X3
Circular plug-in
connector,
to be wired by
user, 5-pin, M12
4
1
Ø19,6
Circular plug-in
connector,
to be wired by
user, 5-pin, M12
Pin pattern, order information
5
2
1
Mat. no.: R901075550
(Cable diameter 6 to 8 mm)
Mat. no.: R901075563
RE 29050/01.08 4WREQ
Hydraulics Bosch Rexroth AG
27/28
Engineering / maintenance notes / supplementary information
Product documentation for IAC-P
Product information RE 29015-P
Technical data sheet for 4WREQ, RE 29050 (this data sheet)
Operating manual RE 29015-B
CAN bus protocol description RE 29015-01-Z
Profibus protocol description RE 29015-02-Z
General information on maintenance and commissioning of hydraulic components
RE 07800 / RE 07900
Commissioning software WIN-PED 6 and documentation on the Internet: www.boschrexroth.com/IAC
Maintenance notes:
–The units are tested in the factory and shipped with default settings.
–Only complete components can be repaired. The repaired components are returned again with the default settings.
User settings are not retained or reloaded. The user is responsible for reloading the corresponding user parameters.
Notes:
–Cut the supply voltage to the valve only in when required for the functional sequence of the machine.
–Electrical signals brought out via control electronics (e.g. signal “ready for operation”) must not be used for switching safety-relevant machine functions! (See also European standard “safety requirements for fluid power systems and components - hydraulics “, EN 982.)
–If electromagnetic interference is to be expected, take suitable measures to safeguard the function (depending on application,
e.g. shield, filter)!
28/28
Bosch Rexroth AG Hydraulics
4WREQ
RE 29050/01.08
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application
can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process of
wear and aging.
High-response valve with integrated
digital axis controller (IAC-R) and
field bus interface
RE 29191/09.10
Replaces: 06.05
1/22
Type 4WRPNH.../24C...
Type 4WRPNH.../24P...
Size 6 and 10
Component series 2X
Maximum operating pressure 315 bar
Maximum flow 100 l/min (Δp = 70 bar)
H7314
Table of contents
Features
Content
Page
Features
1
Ordering code
2
Standard types
3
Symbols
4
Function, section
5 and 6
Technical data
7 and 8
Block diagram/controller functionality
9
Electrical connections, assignment
10 and 11
Characteristic curves size 6
12 and 13
Characteristic curves size 10
14 and 15
Unit dimensions size 6
Unit dimensions size 10
Accessories
Project Planning / maintenance Instructions /
additional Information
16
17
18 to 20
21
– Direct operated high-response valves size 6 and size 10 with
control spool and sleeve in servo quality
– Single-side operated, 4/4 fail-safe position in deactivated
state
– Integrated digital axis control functionality (IAC-R) for:
• Flow control
• Position control
• Pressure control
• p/Q function
• Substitutional position/pressure and position/
force control
• NC functionality (stand-alone operation possible)
– Analog and digital interfaces for command and actual values
• 4 x analog sensors (+/–10 V or 4..20 mA) or
• 1 x length measurement system (1Vss or SSI) and
2 analog sensors
– Command value provision/actual value response analog
(current or voltage) or via field bus
– Analog/digital inputs/outputs configurable
– Field bus connection
• CAN bus with CANopen protocol DS408
• Profibus-DP V0/V1
– Quick commissioning via PC and commissioning software
2/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Ordering code
4WRP
N
H
B
2X M 24
*
Further details in
the plain text
with integrated digital
axis controller and
NC functionality
=N
Control spools / sleeve
Sensor interfaces 4)
A=
X4, M12-5, ±10 V
X7, M12-5, ±10 V
B=
X4, M12-5, ±10 V
X7, M23-12, SSI 5)
C=
X4, M12-5, ±10 V
X7, M23-12, 1 Vss 6)
G = X4, M12-5, 4...20 mA
X7, M12-5, 4...20 mA
H = X4, M12-5, 4...20 mA
X7, M23-12, SSI 5)
=H
Size 6
Size 10
=6
= 10
Spool symbols
4/4-directional design
AB
a 0 b
PT
)(
)(
)( )(
)(
)(
)( )(
)(
)(
)( )(
)( )(
)( )(
)( )(
)(
)( )(
=C
)( )(
)(
A6 =
F6 =
= C4, C1
)( )(
)( )(
)( )(
= C3, C5
)( )(
)( )(
)( )(
24 =
Mounting side of the inductive position transducer
AB
a 0 b
G
b
Field bus interface
CANopen 7)
Profibus DP V0/V1
C=
P=
With symbols C5 and C1:
P → A: qv
B → T: qv/2
P → B: qv/2
A → T: qv
(standard)
M=
=B
Rated flow at 70 bar valve pressure differential
(35 bar / control edge)
Size 6
2 l/min
4 l/min
12 l/min 8)
15 l/min 1)
24 l/min 8)
25 l/min 1)
40 l/min 2)
Size 10
50 l/min
100 l/min
Flow characteristics
Linear
Inflected characteristic curve 3)
Supply voltage 24 V
Seal material
NBR seals
suitable for mineral oils
(HL; HLP) according to DIN 51524
2X =
PT
= 02
= 04
= 12
= 15
= 24
= 25
= 40
= 50
= 100
=L
=P
Command value inputs
±10 VDC
4...20 mA
Component series 20 to 29
(20 to 29: Identical installation
and connection dimensions)
1)
Only in connection with flow characteristics "P"
2)
qv 2:1 only with rated flow = 40 l/min
3)
Inflection 60 % at size 6 with rated flow "15" and
"25", otherwise inflection 40 %
4)
For sensor interfaces "A", "B" or "C" only command
value input "A6" is possible.
For sensor interface "G" and "H" only command
value input "F6" is possible.
5)
Gray code or binary
6)
Adjustable interpolation
7)
Field bus interface CANopen with sensor interface
"B", "C", "G" or "H" only upon request
8)
Only in connection with flow characteristics "L"
Note:
Ordering codes for and technical information on the control valve with integrated digital axis controller (IAC-R) and clock-synchronized PROFIBUS DP/V2 (PROFIdrive profile) can be seen on data sheet 29291.
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
Standard types
Size 6 with CANopen
Size 10 with CANopen
Material no.
Type
Material no.
Type
R901124262
4WRPNH 6 C4 B40P-2X/M/24CA6A
R901125645
4WRPNH 10 C3 B100P-2X/M/24CA6A
R901131590
4WRPNH 6 C4 B15P-2X/M/24CA6A
0811403361
4WRPNH 10 C3 B100L-2X/M/24CA6A
0811403540
4WRPNH 6 C3 B24L-2X/M/24CF6G
R901243764
4WRPNH 10 C3 B100L-2X/M/24CA6B
0811403548
4WRPNH 6 C4 B40L-2X/M/24CA6A
R901243769
4WRPNH 10 C3 B100P-2X/M/24CA6B
0811403541
4WRPNH 6 C3 B04L-2X/M/24CA6A
Size 6 with Profibus DP
Size 10 with Profibus DP
Material no.
Type
Material no.
Type
0811403552
4WRPNH 6 C3 B04L-2X/M/24PA6A
0811403358
4WRPNH 10 C3 B100L-2X/M/24PF6G
0811403575
4WRPNH 6 C3 B40L-2X/M/24PA6B
0811403359
4WRPNH 10 C4 B100L-2X/M/24PF6G
0811403550
4WRPNH 6 C3 B40L-2X/M/24PA6A
R901232766
4WRPNH 10 C4 B100P-2X/M/24PF6G
0811403573
4WRPNH 6 C3 B25P-2X/M/24PA6B
0811403559
4WRPNH 6 C3 B04L-2X/M/24PF6G
0811403531
4WRPNH 6 C3 B40L-2X/M/24PF6G
R901224758
4WRPNH 6 C1 B24L-2X/M/24PF6G
3/22
4/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Symbols
Size 6
A B
a
0
G
b
Linear
b
P T
p: Inflection 60 %
[qn 15.25 l/min]
p: Inflection 40 %
[qn 40 l/min]
Q
Q
Q
C3, C5
C4, C1
C3, C5, C4, C1
Q
C
C
C3, C5, C4, C1
Standard = 1:1, from qn = 40 l/min also 2:1
Size 10
A B
a
0
b
G
b
Linear
p: Inflection 40 %
P T
Q
C3, C5
Q
C4, C1
C3, C5, C4, C1
Q
C
C
C3, C5, C4, C1
5/22
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
Function, section
Structure
The IAC-R valve mainly consists of:
– Direct operated high-response valve (1) with control spool
in servo quality
– Integrated digital axis controller (2) with analog and digital
sensor interfaces and field bus connection (X3)
2
High-response valve with integrated
axis controller with
analog interfaces (X1, X4, X7)
X1
X3
X4
X7
1
2
High-response valve with integrated
axis controller with
analog interfaces (X1, X4)
and digital
sensor interface (X7)
X1
X3
X4
X7
1
6/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Function, section
Functional description
The IAC-R valve (Integrated Axis Controller on the basis of
high-response valves) is a digital high-response valve with
integrated axis controller with the following functionalities:
– Flow control
– Position control
– Pressure control
– p/Q function
The digital integrated control electronics enables the following fault detection:
– Cable break sensors
– Undervoltage
– Temperature of the integrated electronics
– Communication errors
– Watchdog
– Substitutional position/pressure and position/
force control
– NC functionality
– The command value can alternatively be provided via an
analog interface (X1) or via the field bus interface (X3)
– The actual value signals are provided via an analog interface
(X1) and can additionally be read out via the field bus (X3).
– The controller parameters are set via the field bus.
– Separate supply voltage for bus/controller and power part
(output stage) for safety reasons
PC program WinHPT
To implement the project planning task and to parameterize
the IAC-R valves, the user may use the commissioning software WinHPT (see accessories).
– Parameterization
– Programming of NC functionality
– Diagnosis
– Comfortable data management on a PC
– PC operating systems: Windows 2000 or Windows XP
The following additional functions are available:
– Ramp generator
– Internal command value profile
– Release function analog/digital
– Error output 24 V (e.g. as switching signal to PLC/logic and
further valves), max. 1.8 A
– Control output adjustment
• Deadband compensation
• Zero point correction
• Valve inflection compensation
• Friction compensation
• Direction-dependent gain
7/22
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
Technical Data (For applications outside these parameters, please consult us!)
general
Size 6
Size 10
Type
Gate valve, directly operated, with steel sleeve
Actuation
Proportional solenoid with position control, OBE
Type of connection
Plate connection, porting pattern according to ISO 4401
Installation position
Any
Ambient temperature range
°C –20 … +50
Weight
kg
2.7
7.5
hydraulic (measured with HLP46, ϑÖL = 40 °C ± 5 °C)
Hydraulic fluid
Hydraulic oil according to DIN 51524…535, other media
upon request
Viscosity range
Recommended
mm2/s 20 … 100
Max admissible
mm2/s 10 … 800
Hydraulic fluid temperature range
°C –20 … +60
Maximum permitted degree of contamination of the hydraulic fluid
cleanliness class according to ISO 4406 (c)
Class 18/16/13 1)
Direction of flow
According to symbol
hydraulic, size 6
Rated flow at Δp = 35 bar per edge 2)
Max. operating pressure
Limitation of use with regard
to the transition to failsafe
Leakage oil at
100 bar
Ports P, A, B
l/min
2
4
12
bar
15
24/25
40
315
Port T
bar
Spool symbols C3, C5
bar
315
315
315
250
315
315
160
Spool symbols C1, C4
bar
315
315
315
280
250
100
Linear characteristic curve L
cm3/min
< 150
< 180
< 300
-
< 500
< 900
Inflected characteristic curve P
cm3/min
-
-
-
< 180
< 300
< 450
hydraulic, size 10
Rated flow at Δp = 35 bar per edge 2)
Max. operating pressure
Limitation of use with regard
to the transition to failsafe
Leakage oil at
100 bar
l/min
50
(1:1)
50
(2:1)
Ports P, A, B
bar
315
Port T
bar
250
100
(1:1)
100
(2:1)
Spool symbols C3, C5
315
315
160
160
Spool symbols C1, C4
250
250
100
100
Linear characteristic curve L
cm3/min
< 1200
< 1200
< 1500
< 1500
Inflected characteristic curve P
cm3/min
< 600
< 500
< 600
< 600
static / dynamic
Size 6
Size 10
Hysteresis
%
≤ 0.2
Manufacturing tolerance qmax
%
< 10
Actuating time for signal step 0 … 100 %
ms
≤ 10
25
Temperature drift
Zero shift < 1 % at Δϑ = 40 °C
Zero compensation
ex factory ±1 %
Conformity
CE according to EMC directive 2004/108/EC
The footnotes are explained on the following page.
8/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Technical Data (For applications outside these parameters, please consult us!)
electric
Relative duty cycle
% 100 (continuous operation)
Protection class according to EN 60529
Supply
voltage
IP 65 with mounted and locked plug-in connectors
Nominal voltage
VDC 24
Lower limit value
VDC 21
Upper limit value
VDC 36
Max admissible residual ripple
Power consumption
Vss 2 (at supply voltage of 23 V … 34 V)
Size 6
W Max. 40
Size 10
W Max. 60
AD/DA resolution
Analog inputs 12 bit
Analog outputs 10 bit
Protective earthing conductor and shielding
See pin assignment (CE-compliant installation)
Adjustment
Calibrated ex factory, see valve characteristic curve
1)
The cleanliness classes specified for the components must
be adhered to in hydraulic systems.
Effective filtration prevents faults and at the same time
increases the service life of the components.
For the selection of the filters see
www.boschrexroth.de/filter.
2)
Flow at different Δp:
qx = qnom •
Δpx
35
9/22
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
Block diagram/controller functionality
PROFIBUS DP/
CAN bus
1)
1)
X3
X4
Profibus controller /
CANopen controller
1)
X7 1)
Command value
X1 4
U(I) 1)
A
A
3
Switching output
11
5
24 V (load)
1
0 V (control voltage)
for pins 3, 6, 8, 9
10
24 V (control voltage)
9
0 V (load)
2
Protective earthing
conductor
PE
1)
PWM
PID
U
I
Output
stage off
D
Microcontroller
Reference for
command values
Output
stage
EEPROM
A
Actual
value
position
Flash
Oscillator
demodulator
=
~
Supply for output stage and switching output
GND
DC
DC
GNDL
According to ordering code
Controller functionality block
Analog signals (voltage/current) or digital
signals (CANopen or
Profibus DP)
Command variable of command
value
Actual value
(processed)
Actual pressure value
Actual position value
NC functionality
Command variable
generator
Actual value processing
Q control
Actuating variable
of the Q control
System controller variants
Actuating
p/Q control
variable
Position control
Substitutional control of the
system
controller
These variables must be parameterized.
Actuating variable adaptation
b
Enable
Controller
functionality
block
PWM
U
D
G
8 U(I) 1)
A
D
b
Actual value
A
D
PWM
U
D
0
Actual value
6 U(I) 1)
A
a
U
D
A B
Command value
7 U(I) 1)
A
D
P T
U
10/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Electrical connections, assignment
Unit connector pin assignment X1, 11-pole + PE according to EN 175201-804
Pin
Core
marking 1)
1
1
2
2
3
3
4
4
5
5
6
6
±10 V actual value
or dig. Output (to PLC) 2)
4 … 20 mA actual value, load resistance ~330 Ω
or dig. Output (to PLC) 2)
7
7
Command value ±10 V; Re ~130 kΩ
or dig. Input (from PLC) 2)
4 … 20 mA command value; Re = 200 Ω
or dig. Input (from PLC) 2)
8
8
±10 V actual value
or dig. Output (to PLC) 2)
4 … 20 mA actual value, load resistance ~330 Ω
or dig. Output (to PLC) 2)
1)
2)
Assignment of interface A6
Assignment of interface F6
24 VDC (supply for output stage and power switching signal)
0V
load zero (for output stage)
Release input 8.5 … 24 VDC = function, Re ~10 kΩ
Command value ±10 V; Re ~130 kΩ
or dig. Input (from PLC) 2)
4 … 20 mA command value; Re = 200 Ω
or dig. Input (from PLC) 2)
Reference for command values
9
9
24 VDC (control voltage for signal part and bus)
10
10
0 V reference potential for pin 3, 6, 8 and 9
11
11
Switching output 24 V (error signal or power switching signal) max 1.8 A
PE
Green-yellow
Protective earthing conductor (connected directly to metal housing)
Core marking of the connection lines for
line socket with cable set (see accessories)
X1
4
Selection via commissioning software
5
10
3
6
11
9
2
7
8
1
Unit connector pin assignment for CAN bus "X3" (code A), M12, 5-pole, pins
Pin
Assignment
1
n.c.
2
n.c.
3
CAN_GND
4
CAN_H
5
CAN_L
External screen on both sides of the metallic
housing of the plug-in connection.
3
Internal screens are not required.
Transmission rate kbit/s
Bus address
20 to 1000
1 to 127
2
5
4
1
Unit connector pin assignment for Profibus DP "X3" (code B), M12, 5-pole, socket
Pin Assignment
1
VP
2
RxD/TxD-N (A line)
3
D GND
4
RxD/TxD-P (B line)
5
Shield
Transmission rate
Bus address
up to 12 MBaud
1 to 126
4
1
3
The galvanically separated voltage +5 V (pin 1 - VP) at the socket allows for passive termination of the profibus.
5
2
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
11/22
Electrical connections, assignment
Analog sensor interfaces, connection "X4" and "X7" (code A), M12, 5-pole, socket
Pin Assignment of voltage interface
Assignment of current interface
1
Supply 24 VDC
Supply 24 VDC
2
Signal 3 (X4) / 4 (X7), (–10 … +10 V)
Signal 3 (X4) / 4 (X7), (4 … 20 mA)
3
Zero 0 V
Zero 0 V 1)
4
Signal 1 (X4) / 2 (X7), (–10 … +10 V)
Signal 1 (X4) / 2 (X7), (4 … 20 mA)
5
Shield
Shield
1)
1
2
4
5
3
Do not connect to 2-wire pressure
transducer
Attention: The analog sensor interfaces at the connections X4 and X7 are not coded.
Danger of confusing the same! The user has to ensure proper wiring!
Digital sensor interface 1Vss or SSI measurement system "X7", M23, 12-pole, socket
Pin Assignment 1Vss
Assignment SSI
1
B
0V
2
Sense +5 V 1)
Data
2
3
R
Clock
3
4
R
n.c.
5
A
n.c.
6
A
n.c.
7
n.c.
n.c.
8
B
n.c.
9
n.c.
1
10
9 8
7
12
11
4
6
5
24 V
1)
10
0V
11
Sense 0 V 1)
12
1)
+5 V
Data
Clock
n.c.
Note:
The sense signal is not analyzed.
1)
Recommendation:
Connect the voltages +5 V (pin 12) and +5 V-Sense (pin 2), as well as 0 V (pin 10) and 0 V-Sense (pin 11) for transducer supply.
Note:
We recommend connecting the screens on both sides over the metallic housings of the plug-and-socket-connectors.
Using connector pins will affect the effectiveness of the screen!
Internal screens are not required.
12/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Characteristic curves size 6 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Pressure gain
ΔpA→B [%pP]
100
80
60
40
20
Command value [%] –4 –3 –2 –1
1
–20
2
3
4 Command value [%]
–40
–60
–80
–100
ΔpB→A [%pP]
Bode diagram
A
⎯ [dB]
E
2
0
%
U E ±5
%
100
UE±
–2
–4
–6
ϕ [°]
–180
–10
–140
–120
–100
U
E
U ±
E 5
%
–160
±10
0%
–8
–80
–60
–40
1
10
20
40 60 80 100
–20
0
200 300
f [Hz]
Amplitude
Phase
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
13/22
Characteristic curves size 6 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Flow - signal function
L: Linear
Q [%]
qvA: qvB = 1:1
100
80
60
B-T q : q = 2:1
vA vB
40
20
–100 –80 –60 –40 –20
Command
value [%]
Command
20 40 60 80 100 value [%]
–20
–40
P-B
–60
–80
–100
Q [%]
P: Inflection 60 %
P: Inflection 40 %
Q [%]
Q [%]
100
80
100
80
60
40
–100–80–60–40 –20
Command
value [%]
60
40
20
Command
20 40 60 80 100 value [%]
–20
–40
–60
–80
–100
–100 –80 –60 –40 –20
Command
–20
value [%]
P-B
–40
qvA: qvB = 1:1
B-T q : q = 2:1
vA vB
20
Command
20 40 60 80 100 value [%]
–60
–80
–100
Q [%]
Q [%]
Fail-safe position
A
Leakage oil at
B
G
Flow at
b
P
T
A
B
Leakage oil at
G
b
P
100 bar
T
Fail-safe p =
0 bar =>
7 ms
p = 100 bar => 10 ms
∆p = 35 bar
100 bar
P→A
50 cm3/min
P→B
70 cm3/min
A→T
10 ... 20 l/min
B→T
7 ... 20 l/min
P→A
50 cm3/min
P→B
70 cm3/min
A→T
70 cm3/min
B→T
50 cm3/min
Enable "off" or internal shut-off in case of error
UB ≤ 18 V or I ≤ 2 mA (at 4…20 mA signal)
14/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Characteristic curves size 10 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Pressure gain
ΔpA→B [%pP]
100
80
60
40
20
Command value [%]
–4 –3 –2 –1
1
–20
2
3
4
Command value [%]
–40
–60
–80
–100
ΔpB→A [%pP]
Bode diagram
A
⎯ [dB]
E
2
0
90%
%
UE ± 5
UE ±
–2
–4
ϕ [°]
–200
–180
–8
–160
U ±
E 90
%
–10
UE ±
5%
–6
–140
–120
–100
–80
–60
–40
–20
0
1
10
20
40 60 80 100
200 300
f [Hz]
Amplitude
Phase
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
15/22
Characteristic curves size 10 (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Flow - signal function
L: Linear 1:1
L: Linear 2:1
Q [%]
100
80
60
40
20
–100 –80–60 –40–20
Command
value [%]
Q [%]
100
80
60
40
Command
20 40 60 80 100 value [%]
–20
–40
20
–100 –80–60 –40–20
B-T
qvA: qvB = 2:1
Command
20 40 60 80 100 value [%]
–20
–40
Command
value [%]
P-B
–60
–80
qvA: qvB = 1:1
P-A
–60
–80
A-T
–100
Q [%]
–100
Q [%]
P: Inflection 40 % 1:1
P: Inflection 40 % 2:1
Q [%]
100
Q [%]
100
80
60
40
qvA: qvB = 1:1
P-A
80
60
40
20
–100 –80 –60 –40–20
Command
Command
20 40 60 80 100 value [%]
–20
value [%]
–40
Command
value [%]
–60
–80
20
–100 –80 –60 –40 –20
P-B
A-T
B-T
qvA: qvB = 2:1
Command
20 40 60 80 100 value [%]
–20
–40
–60
–80
–100
Q [%]
–100
Q [%]
Fail-safe position
A
Leakage oil at
B
T
A
B
Flow at
Leakage oil at
G
b
P
50 cm3/min
P→B
70 cm3/min
∆p = 35 bar
A→T
10 ... 20 l/min
qn = 50/100 l/min
B→T
7 ... 20 l/min
100 bar
P→A
50 cm3/min
P→B
70 cm3/min
A→T
70 cm3/min
B→T
50 cm3/min
G
b
P
P→A
100 bar
T
Fail-safe p =
0 bar => 12 ms
p = 100 bar => 16 ms
Enable "off" or internal shut-off in case of error
UB ≤ 18 V or I ≤ 2 mA (at 4…20 mA signal)
16/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Unit dimensions size 6 (dimensions in mm)
4
ca. 130 mm
22
49
55
132
77
ca. 150 mm
24
175
1
3
2
46
45
5
14
F1
6
T
0,01/100
F2
48
8,5
Rzmax 4
A
P
F4
B
F3
G
Required surface quality of the
valve mounting face
68,5
1 Valve housing
2 Control solenoid with position transducer
3 O-ring 9.25 x 1.78 (ports P, A, B, T)
4 Integrated digital control electronics
5 Name plate
6 Machined valve mounting face, porting pattern
according to ISO 4401-03-02-0-05
Valve mounting screws
(not included in scope of delivery)
4 units of hexagon socket head cap screws according to
ISO4762-M5x30-10.9-N67F 821 70
(galvanized according to Bosch standard N67F 821 70)
MA = 6+2 Nm
Mat. no. 2910151166
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
17/22
Unit dimensions size 10 (dimensions in mm)
4
ca. 130 mm
30
68
81
10
155
77
ca. 150 mm
35
207
1
3
2
70
60
5
243
50,8±0,2
32,5±0,2 21
73
32
F1 P
F2
6
0,01/100
Rzmax 4
A
B
T
T1
F4
Required surface quality of the
valve mounting face
F3
104,5
1 Valve housing
2 Control solenoid with position transducer
3 O-ring 12.0 x 2.0 (ports P, A, B, T, T1)
4 Integrated digital control electronics
5 Name plate
6 Machined valve mounting face, porting pattern
according to ISO 4401-05-04-0-05
Deviating from the standard:
– Port T1 is provided additionally
Valve mounting screws
(not included in scope of delivery)
4 units of hexagon socket head cap screws according to
ISO4762-M6x40-10.9-N67F 821 70
(galvanized according to Bosch standard N67F 821 70)
MA = 11+3 Nm
Mat. no. 2910151209
18/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Accessories for parameterization (not included in scope of delivery)
The following is required for the
parameterization with PC:
CANopen
Profibus DP
1 Interface converter (USB)
VT-ZKO-USB/CA-1-1X/V0/0
VT-ZKO-USB/P-1-1X/V0/0
Mat. no. R901071963
2 Start-up software
Mat. no. R901071962
WinHPT
Download from www.boschrexroth.com/IAC
3 Connecting cable, 3 m
D-Sub / M12 (coding A),
D-Sub / M12 (coding B),
Mat. no. R900751271
Mat. no. R901078053
2
3
1
Hydraulics Bosch Rexroth AG
RE 29191/09.10 4WRPNH
19/22
Accessories, port X1 (not included in scope of delivery)
Mating connector for X1
Mating connector according to
EN 175201-804
(12-pole, metal design)
• Mating connector (construction set) for
a cable diameter of 12-15 mm
Material no. R901268000
• Mating connector with 5 m cable,
12 x 0.75 mm2 with cable shield,
assembled
Material no. R901272854
• Mating connector with 20 m cable,
12 x 0.75 mm2 with cable shield,
assembled
Material no. R901272852
SW22
SW24
7
4
5
6
3
10
11
2
9
8
1
M26x1,5
41
91
Accessories, sensor connections (not included in scope of delivery)
Description
View, dimensions
X4, X7 (analog sensors)
ca. 61
3
2
Ø19,6
Plug-in connector, 5-pole,
M12 x 1, pins, A coding,
metal design
Pole image, order details
5
4
1
Mat. no.: R901075542
(cable diameter 4 … 6 mm)
X7 (digital sensors,
1 Vss and SSI)
8
Ø26
Plug-in connector,
12-pole, M23, pins, soldered joint, metal design
with cap nut
61,1
9 1
7
12 10
2
6
11
3
5
4
Mat. no.: R901076284
(cable diameter up to 10.5 mm)
20/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Accessories, CAN bus (A coding) (not included in scope of delivery)
Description
View, Dimensions
X3
Straight mating connector
from metal.
ca. 56
1
2
Ø19,6
Round plug-in connector, processible, 5-pole,
M12 x 1
Pole image, order details
4
5
3
Mat. no.: R901076910
(cable diameter 6-8 mm)
M12 cap
Dust protection
Mat. no.: R901075564
Accessories, profibus (B code) (not included in scope of delivery)
Description
View, Dimensions
X3
Straight line coupling plug
from metal.
ca. 61
4
1
Ø19,6
Round plug-in connector, processible, 5-pole,
M12 x 1
Pole image, order details
5
2
3
Mat. no.: R901075545
(cable diameter 6-8 mm)
Further profibus participants can be connected e.g. with a Y cable (can be ordered at HARTING, Mat. no. TB61042030039).
M12 protective cap
Mat. no.: R901075563
RE 29191/09.10 4WRPNH
Hydraulics Bosch Rexroth AG
21/22
Project Planning / Maintenance Instructions / Additional Information
Product documentation for IAC-R
Data sheet 29191 (this data sheet)
Declaration on environmental compatibility 29191-U
Operator's manual
CANopen 29090-B-01
Profibus
29090-B-02
General information on the maintenance and commissioning of hydraulic components
07800 / 07900
Commissioning software and documentation on the Internet: www.boschrexroth.com/IAC
Maintenance instructions:
– The devices have been tested in the plant and are supplied with default settings.
– Only complete units can be repaired. Repaired devices are returned with default settings.
User-specific settings are not maintained. The operator will have to retransfer the corresponding user parameters.
Notes:
– Connect the valve to the supply voltage only when this is required for the functional processes of the machine.
– Electric signals taken out via control electronics (e.g. signal "ready for operation") may not be used for the actuation of
safety-relevant machine functions! (See also the European standard "Safety requirements for fluid power systems and their
components - Hydraulics", EN 982.)
– If electromagnetic interference is to be anticipated, suitable measures must be taken to ensure the function (depending on
the application, e.g. shielding, filtration)!
22/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
RE 29191/09.10 4WRPNH
Hydraulics Bosch Rexroth AG
23/22
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
24/22
Bosch Rexroth AG Hydraulics
4WRPNH RE 29191/09.10
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax
+49 (0) 93 52 / 18-23 58
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies
Service
Automation
Pneumatics
Mobile
Hydraulics
RE 30050/03.04
Replaces: 11.02
Analog position controller
Type VT-MACAS
Series 1X
Type VT-MACAS
List of contents
Contents
Features
Ordering data
Preferred types
Front panel
Block diagram
Technical data
Additional information
Device dimensions
Features
Page
1
2
2
2
3
4
5
6
–
–
–
–
–
–
–
–
–
Design: Module for snapping onto DIN rails
Actuation of valves with on-board electronics
Enabling input
Open-circuit detection for feedback signal cable
Short-circuit-proof interfaces
Measurement taps on front panel
Deadband compensation can be deactivated
Position: PT1 control
Velocity control possible in conjunction with a speedometer:
PI control
– Cylinder area ratio adjustment
© 2004
by Bosch Rexroth AG, Industrial Hydraulics, D-97813 Lohr am Main
All rights reserved. This work may not be reproduced, stored, edited, copied or circulated in whole or in part,
by electronic means or otherwise, without the prior written consent of Bosch Rexroth AG. Violations will result in liability for damages.
This work has been compiled with the greatest care, and all the information therein has been checked to ensure correctness.
We must reserve the right to make changes on the grounds of continual product development. No liability can be accepted for incomplete
or inaccurate information.
VT-MACAS
1/6
RE 30050/03.04
Ordering data
VTHydraulic component
Axis control
M A
C
A
S
-
-
/
/
=A
I=
Type
Controller
Option
No code
Version with
supply input
Version with
current input
=C
Actuation
Analog
V0 =
Customer version
Catalogue version
=A
Function
Position control
Series
Series 10 to 19
1X =
=S
500 =
Serial numbers for types
Standard version without valve amplifier function
Preferred types (available at short notice)
Material no.
Type VT-MACAS
For valve types
0 811 405 139
0 811 405 140
VT-MACAS-500-10/V0
VT-MACAS-500-10/V0/I
Valves with on-board electronics
Valves with on-board electronics
Front panel
RE 30050/03.04
2/6
VT-MACAS
Block diagram with terminal assignment
VT-MACAS
3/6
RE 30050/03.04
Technical data (For device applications beyond the stated values, please consult us!)
Format/design
Fastening/connection
Temperature range
Power supply
(8), (9)
Current rating
Signal input
VT-MACAS-500-10/V0
(1), (2)
VT-MACAS-500-10/V0/I
Feedback signal
VT-MACAS-500-10/V0
(3), (4)
VT-MACAS-500-10/V0/I
Valve signal
(5), (6), (7)
Deadband compensation
Enable signal (10)
Fault signal (11)
IN POS signal (12)
Ramp ranges
Area ratio adjustment
AK:AR
Feedback signal adjustment
Type of controller
Valve zero
Special features
RE 30050/03.04
(86 x 110 x 95) mm/module
DIN rail/connector + terminals
0 ... 70 °C; storage: –20 ... +70 °C
UB = 24 Vnom/batt.: 21 ... 40 V DC
Single-phase full wave: 21 ... 28 V DCeff
Max. 200 mA
Uset: ±10 V, difference amplifier
Ri = 100 kΩ
Iset: 4 ... 20 mA Rsh = 200 Ω
Ufeed: ±10 V, difference amplifier
Ri = 100 kΩ
Ifeed: 4 ... 20 mA Rsh = 200 Ω
UV = ±10 V (max. 10 mA) or
IV = 4 ... 20 mA (average 12 mA)
Can be deactivated,
effective in a range of ± 4 %
8.5 ... 40 V DC
No fault: 24 Vnom (UB) max. 50 mA
Fault: < 2 V
IN POS: 24 Vnom (UB) max. 50 mA
Not IN POS: < 2 V
I: 0.1 ... 1 s
II: 1 ... 10 s
Min. 1:1; max. 1:4
Zero: –5 ... 10 %
Gain: 50 ... 110 %
Position: PT1
Velocity: PI
±5%
– Module can be switched from position to velocity control
– Position window can be switched over
– Measurement taps on front panel
– Short-circuit-proof interfaces
4/6
VT-MACAS
Additional information
Applications
This controller module enables simple position or velocity
control actions to be effected, in combination with Bosch
Rexroth servo cylinders with analog position measurement
systems (potentiometers). Since the signals are processed in an
analog manner and the module is only equipped with the most
essential features required for performing a control action,
we were able to keep the cost of the drive low. A further
speciality of this module is that it can be switched over internally
(front panel) to velocity control, and there is a version for
voltage interface and a version for current interface, related to
the setpoints and feedback signals.
Position control
The setpoint and feedback signals of the position are compared
and the difference transmitted to the valve amplifier. In the event
of an abrupt change in the input signal, the system reacts with
maximum dynamics. The times for accelerating or braking a load
are limited either by the available power or the system gain.
When a ramp function acts as an input value, the load is moved
at a constant speed.
Velocity control*
The setpoint and feedback signal of velocity are compared and
the difference transmitted to the valve amplifier. Through the
process of integration, the signal is amplified to such an extent
that even the smallest error is eliminated.
When a ramp function acts as an input signal, progressive
acceleration or deceleration with a constant value takes place.
* Only possible with a speedometer.
VT-MACAS
5/6
RE 30050/03.04
Device dimensions (in mm)
Wall mounting
86 x 110 x 95
DIN rail mounting
Bosch Rexroth AG
Industrial Hydraulics
D-97813 Lohr am Main
Zum Eisengießer 1 D-97816 Lohr am Main
Telefon 0 93 52/18-0
Telefax 0 93 52/18-23 58 Telex 6 89 418-0
eMail [email protected]
Internet www.boschrexroth.de
RE 30050/03.04
The information contained herein is intended
to serve purely as a product description.
The information we have provided
cannot be used as evidence of a particular
aspect or of suitability for a particular purpose.
Please note that our products are subject
to the natural processes of ageing and wear.
6/6
VT-MACAS
p/Q closed-loop control amplifier
RE 30058/06.12
Replaces: 03.04
1/14
Type VT-VARAP1-...-2X/...
Component series 2X
Table of contents
Contents
Features
Page
– Suitable for controlling direct and pilot operated control valves
Features
1
– Amplifier with additional electronics (daughter card)
Ordering code, accessories
2
– Analog amplifiers in Europe format for installation in 19" racks
2
– Valve position control with PID behavior
Front plate
Block diagram with pin assignment
3, 4
– Pressure control with external pressure load cell
Technical data
5, 6
– Controlled output stage
Additional information
6
– Enable input
Examples
7
– Outputs short-circuit-proof
Function
8
– Adjustment possibilities – Zero point valve
9
Mode setting
10
– Cable break detection for actual value cable and pressure sensor
General notes
11
– Fast energization and fast deletion for short actuating times
Ideal development
12
– External controller shut-off
Adjustment protocol
13
Unit dimensions
14
– Suitable for pressure sensors (1...6 V, 0...10 V, 4...20 mA),
see data sheet 30271
Project planning / maintenance instructions /
additional information
14
Block diagram daughter card
Notice:
The photo is an example configuration.
The delivered product differs from the figure.
2/14
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
Ordering code, accessories
VT- V
Hydraulic component
(control)
Axis control
A
R
A
P
1
2X V0
Option
no code = High-response valve size 6/10
direct operated
5/3V =
p/Q valve size 10
direct operated
2STV =
High-response valve
pilot operated
3/2V = High-response valve pilot operated
Control line A → X
=A
Valve type
High-response valve
=R
Control
Analog
=A
Function
p/Q control
=P
V0 =
Output stages
1 output stage
=1
2X =
527 =
537 =
Customer version
Catalog version
Component series 20 to 29
(20 to 29: Unchanged technical data
and pin assignment)
Serial number for types
2.7 A solenoid
3.7 A solenoid
Preferred types
Amplifier type
Material number
For high-response valves with electrical position feedback
VT-VARAP1-527-20/V0
0811405152
4WRPH6...
VT-VARAP1-537-20/V0
0811405153
4WRPH10...
VT-VARAP1-537-20/V0/5/3V
0811405154
5WRP10...
VT-VARAP1-527-20/V0/2STV
0811405155
4WRL...
VT-VARAP1-527-20/V0/3/2VAX
0811405156
3WRCBH25...50...
Suitable card holder:
– Open card holder VT 3002-1-2X/32F
(see data sheet 29928).
Only for control cabinet installation!
Front plate
LED green
Command value signal Q
Enable
ON
LED red
UB < UB min.
UB
1
13
Pot Qmax
Qmax
TP Q
5
9
1
Zero point adjustment
Qmax
13
KP
Regler
off
LED
Hex KI
5
KI
ON
LED
5
KD
Hex KD
P
Pnull
Pot p gain
Pot p zero
9
Pressure controller Off
Hex KP
Cable break pressure sensor
1
13
QA
9
+ 5%
+UE
–UE
–
–
+
+
valve
Lvdt
QB
LED yellow
Cable break
P
TP p
0V
TP 0 V
Pressure controller effective
Pressure sensor
6...40 V
Test (p)
p controller
OFF
Sensor
supply
Command
value p
p sensor
2-1
2-3
1-2
1-3
z10
z6
b30
–15 V
+15 V
0V
0...+10 V
1...6 V/0...10 V
z12
1-6
b18
1-5
1-7
z24
b16
1-4
b10
2-4
2-2
z18
b20
Ref. 0 V
4...20 mA z14
p controller is working
0...+10 V
Command
value Q
z20
z22
24 V
0V
z16
b14
b12
b32
+10 V
max 40 V=
0... + 10 V
UE
0V
Error
Enable
Control zero
Potentiometer supply
z32
+UB
+
Qmax
100 k
100 k
max 40 V
pzero
D
pgain
Differential amplifier
24 V=
max100 mA
+UB
100 k
8.5 V=
10 V/10 mA
+10 V/10 mA
+5 %
I
15 V
Cable
break
P
Safety logic
Zero point
adjustment
3-1 3-5
green
On
+15 V
10 V
+10 V
1-1
L –0 V
3-2
+15 V
3-3
–15 V
3-4
St.–0 V
Lvdt.
+ 15 V
+ 10 V
DC
Size 6
Size 10
ΔS
yellow
red
DC
+
+UB
b22
+UB
b8
b6
b30
z30
Ref -0- b24
+10 V
z28
b2
b4
z4
z2
U
s
1 2
1 2 3 4
z28 Control zero
b2 Power zero
0 V Neutral point
+UB 24V = Supply
RE 30058/06.12 VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
Block diagram with pin assignment
0811405152, 0811405153, 0811405154
3/14
1-7
1-6
2-4
1-5
2-1
2-3
1-2
1-3
z24
b18
Ref. 0 V
4...20 mA z14
b16
z12
Sensor
supply
Command
value p
z10
z6
b30
–15 V
+15 V
0V
0...+10 V
1...6 V/0...10 V
green
+
pzero
D
pgain
On
I
3-1 3-5
+5 %
P
Cable
break
Zero point
adjustment
Safety logic
15 V
+15 V
10 V
+10 V
1-1
L –0 V
3-2
+15 V
3-3
–15 V
3-4
St.–0 V
Lvdt.
yellow
red
+ 15 V
+ 10 V
DC
ΔS
ΔS
b26
z28
b2
b4
b22
+UB
b8
b6
U
U
b30
z30
Ref -0- b24
+10 V
b30
z30
b28
Ref -0-
+10 V
4WRL... or
3WRCBH25...50
DC
+
z4
z2
s
s
1 2
1 2 3 4
z28 Control zero
b2 Power zero
0 V Neutral point
+UB 24V = Supply
1 2 3 4
Bosch Rexroth AG Hydraulics
p sensor
+UB
max 40 V
Differential amplifier
Qmax
100 k
100 k
24 V=
max100 mA
+UB
100 k
8.5 V=
10 V/10 mA
+10 V/10 mA
+UB
0811405155,
0811405156
p controller is working
1-4
b10
6...40 V
p controller
OFF
2-2
0...+10 V
Test (p)
b20
z18
0...+10 V
UE
0V
z20
z22
24 V
0V
z16
b14
b12
b32
+10 V
max 40 V=
Command
value Q
Error
Enable
Control zero
Potentiometer supply
z32
4/14
VT-VARAP1-...-2X/... RE 30058/06.12
Block diagram with pin assignment
RE 30058/06.12 VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
Technical data (For applications outside these parameters, please consult us!)
Supply voltage
UB at z2 – b2
Nominal 24 V =
Battery voltage 21...40 V,
Rectified alternating voltage Ueff = 21...28 V
(one-phase, full-wave rectifier)
Smoothing capacitor, separately
at z2 – b2
Recommendation: Capacitor module VT 11110 (see data sheet 30750)
(only necessary if the ripple of UB > 10 %)
Valve solenoid, max.
Current consumption, max.
A/VA 2.7/40 (size 6)
3.7/60 (size 10)
A 1.7
2.7
The current consumption may increase with min. UB
and extreme cable length to the control solenoid
Power consumption (typical)
W 37
55
Input signal (command value)
b20: 0...±10 V
Differential amplifier
z20: 0...±10 V
(Ri = 100 kΩ )
Input signal (command value p)
z12: 0...10 V
Differential amplifier
z10: 0 V
Actual value from the pressure sensor
z14: 4...20 mA – Current input
b16: 0...+10 V/1...+6 V – Voltage input
b18: 0 V – Reference
Pressure controller OFF
b10: 6...40 V =
External enquiry pressure controller active
z24: 24 V/0.1 A max.
Limit frequency
For applications ≦ 30 Hz
Signal source
Potentiometer 10 kΩ
Supply with ±10 V from b32, z32 (10 mA) or external signal source
Enable output stage
At z16, U = 8.5...40 V, Ri = 100 kΩ, LED (green) on front plate lights up
Sensor supply
z6: +15 V/35 mA, Ri ~ 25 Ω
Position transducer Supply
b30: –15 V (25 mA)
z30: +15 V (35 mA)
Pilot control valve
Actual value signal
b22: 0...±10 V, RL = 10 kΩ/Ref. b24
Main stage
Actual value reference b26: 0...±10 V, RL = 10 kΩ/Ref. b28
Solenoid output
Clocked current controller
b6 – b8
Imax 2.7 A
3.7 A
Cable lengths between amplifier and valve
Solenoid cable:
up to 20 m 1.5 mm2
20 to 60 m 2.5 mm2
Position transducer: 4 x 0.5 mm2 (shielded)
Pressure sensor:
4 x 0.5 mm2 (shielded)
Special features
Cable break protection for actual value cable,
Position control with PID behavior,
Pulsed output stage,
Fast energization and fast deletion for short actuating times,
Short-circuit-proof outputs,
Controller shut-off
Adjustment
Zero point via trimming potentiometer ±5 %
Command value attenuator Q
Pressure controller KP, KI and KD
Sensitivity pressure load cell
Zero point pressure load cell
LED displays
green: Enable
yellow: Cable break position transducer
red:
Supply voltage (UB too low)
yellow: Pressure controller OFF
yellow: Pressure controller is working
both yellow LEDs are flashing: Cable break pressure sensor
}
}
5/14
6/14
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
Technical data (For applications outside these parameters, please consult us!)
Error message
– Cable break actual value
– UB too low
– ±15 V stabilization
Circuit board format
z22: Open collector output to +UB
Max. 100 mA; no error: +UB
mm (100 x 160 x approx. 35) / (W x L x H)
Europe format with front panel 7 TE
Connector DIN 41612 – F32
°C 0...+70
°C –20...+70
m 0.49 kg
Plug-in connection
Ambient temperature
Storage temperature range
Weight
Notice:
Power zero b2 and control zero b12 or b14 or z28 must be separately led to the central ground (neutral point).
Additional information
Applications
The p/Q closed-loop control amplifiers consist of a basic
card with front plate containing the valve amplifier with position control as well as an attached daughter card on which
the actual pressure control has been realized.
These amplifiers are only supplied as complete combinations.
In connection with the corresponding high-response valves
(see table page 2) and pressure sensors (sensor signal 1...6 V, 0...10 V or 4...20 mA), flows can be controlled
and pressures in closed control loops can be regulated.
The input variables are the pressure p and flow Q command
values. Pressure and valve spool path are fed back as actual values.
The combination of valve amplifier and p/Q controller
takes effect:
a) As long as pcommand < pactual as flow control,
i.e. the pressure control does not take effect, yet.
b) With pcommand ≧ pactual as pressure control, i.e. the flow
is reduced until pactual = pcommand. The pressure control
works only with a positive command value voltage at z20.
The command value Q corresponds to the spool path as
long as the pressure control does not take effect, yet, i.e.
pcommand > pactual or if the pressure controller is switched off
(DIL 4 OFF). The command value Q may range between
UE = 0...±10 V. For the dynamic pressure control there
should, however, in addition to the command value p also
be a command value Q1 UE ≧ 2...+10 V.
RE 30058/06.12 VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
7/14
Examples
Example 1
Pressure control in a cylinder chamber for achieving a constant clamping force.
Command value p
+
p
U
Pressure controller
Actual value p
A B
G
P T
Limiter
Basic card
Command
value Q
Daughter card
Example 2
Flow with load compensation controlled via pressure compensator and the pressure regulated in the closed control
loop (pressure cut off).
Command value p
+
p
U
Pressure controller
Actual value p
A B
p controller OFF
G
P T
Limiter
Pressure compensator
Basic card
Daughter card
Command
value Q
8/14
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
Function
The combination of basic card and daughter card is shown
in the block diagrams on page 3 and 4. Details of the daughter card, i.e. the pressure control, result from a detailed
block diagram on page 9.
The command value p (z12) is specified by the user by
a voltage 0...+10 V, e.g. by means of a potentiometer which
can be supplied from z32/b12 (z10 to 0 V).
The actual value p is supplied by a pressure sensor. Optionally, sensors with current signal interface 4…20 mA or voltage signal interface 1…6 V and/or 0…10 V can be used.
Zero point and sensitivity of the sensor can be set at the
front plate. Cable break of the pressure sensor is signalized
(LEDs flash) if the sensor is supplied at z6.
Command and actual value are compared in the summing
point which is moreover affected by a differentiated actual value.
Principle of the control loop
The control deviation is amplified by a PID controller and
reaches a limiter superimposing the command value Q with
the pressure controller signal if pcommand ≦ pactual.
As long as pcommand > pactual or if the command value Q ranges between 0…–10 V, the limiter and thus the pressure control do not take effect and there is simple flow control.
The characteristic of the PID controller and the D element can be roughly set by means of the DIL switch on the
daughter card and finely by means of the HEXCODE switch
on the front plate. If the pressure is regulated, this condition
is displayed on the front plate (LED) and can be used for
switching purposes via an acknowledgement output (z24).
However, the pressure control can also be switched off so
that there is only flow control, independent of pactual.
Command value p
P element
+
Actual value p
KP
D element
TV
Pressure increase
TI
I element
Command
value Q
Basic card
Limiter
Pressure sensor connection versions
Usup
P
I
Isig
z6
z14
b18
b12
Usup
P
U
0 V/
Usig
z6
b18
b16
b18
b12
Usup
0 V/
Usig
P
U
0 Vsig
z6
b12
b16
b18
p 0...+10 V
1...6 V/0...10 V
4...20 mA
0V
6...40 V
Command value signal p
p sensor
Supply p sensor
p controller OFF
from the basic card
2-1
2-3
z10
z12
2-2
z18
TP2
1-5
1-6
b18
b16
1-3
z8
2-4
1-2
z6
z14
1-4
b10
3-1
*
*
+
–
DIL1
+
DIL2
Error signal
DIL4
DIL3
pzero
+
+
Cable break p sensor
100 k
100 k
100 k
–15 V
+15 V
Leakage oil
A
P6
Command value signal Q
200 Ω
P1
(Q max )
pgain
KD
Command value
signal p
S3
+
DIL6-10
Controller active
Pressure controller
OFF
Limiter
S2
KI
+
S1
DIL11-16
KP
Default
settings "I"
DIL5
+
+UB
–UB
Command
value p/Q
1-7
3-5
St – 0 V
TP3 (0 V)
L –0 V
+15 V
–15 V
is working
z24 p controller
Q
TP1
0...+10 V
to the basic card
RE 30058/06.12 VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
Block diagram daughter card
9/14
10/14
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
Mode setting (DIL switch, daughter card)
DIL 16...0
DIL
no.
0
1
2
Status Function
–
ON
OFF
ON
OFF
3
ON
OFF
4
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
ON
ON
ON
ON
without function
Pressure sensor
signal
Pressure sensor
amplification
Cable break
monitoring
pressure sensor
Pressure controller
1...6 V/0...10 V
4...20 mA
2)
pSYS ≙ ∼ pNOM3)
pSYS ≙ ∼ 0.5 pNOM
On
Off
On
Off
5
Valve output signal
not inverted
inverted
6
Pressure build-up normal
reduced 1)
7
Pressure
normal
reduced 1)
D reduction
8
Share high
(9, 10 = OFF)
9
Share medium
(8, 10 = OFF)
10
Share low
(8, 9 = OFF)
11
Share = 0
(12 = OFF)
I
12
Share available
(11 = OFF)
13
Reduced pressure Valve opening in
reduction
case of pressure
reduction
< approx. 15 %
P
OFF
ineffective
14
ON
Share low
(16 = ON/15 = OFF)
15
ON
Share medium
(14, 16 = OFF)
16
ON
Share high
(14, 15 = OFF)
1) With DIL 6 and 7 = OFF, DIL 8...10 is ineffective
2)
pSYS
3)
pNOM = Nominal sensor pressure
= System pressure
RE 30058/06.12 VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
11/14
General notes:
Setting during the commissioning is effected using potentiometers and HEXCODE switches on the front plate as well
as using DIL switches on the daughter card bottom side.
Test points for voltage measurements as well as LED displays are located on the front plate. The measured values
generally refer to the test point 0 V. The test points may only
be loaded with measuring instruments RL ≧ 10 kΩ. Overload
impairs the control function and/or the printed circuit board
is damaged.
A: Adjustment of the valve zero point (basic card
front plate)
1) DIL 4 OFF (pressure controller OFF)
2) Applying the voltage and pressure supply
3) Command value specification Q = 0 V
4) Use the "Zero"
potentiometer to bring the cylinder to a standstill
Before the commissioning, the basic settings of the as-delivered
state are to be checked.
In the card comparison, proceed in the order of the
points shown:
D: Controller adjustment
The P, I and D shares of the closed-loop control amplifier are to be optimized according to the properties of the
control distance, the disturbance variables and the static
and dynamic requirements on the control result.
1) Pressure controller ON – DIL 4 ON
2) Connection of an oscilloscope at terminals z18 and
b12 (0 V) ➝ pactual
3) Usefully connection of a 2nd oscilloscope channel at
z2 and z10 (0 V) ➝ pcommand
4) DIL 6 and DIL 7 serve to compensate dynamic differences in the pressure build-up and reduction in
the system
DIL 6
ON
= Normal application
OFF = Special application
DIL 7
ON
= Normal application
OFF = Special application
5) DIL 13 – reduces the pressure reduction
by means of a valve opening
< approx. 15 %
ON
= Special application
OFF = Normal application
B: Pressure sensor comparison
1) Sensor type selection
DIL 1 ON
≙ UA = 1...6 V/0...10 V
OFF
≙
UA = 4...20 mA
2) Sensor amplification selection
DIL 2 ON
if pSYS ~ pNOM
OFF if 0.5 · pNOM ≦ pSYS ≦ pNOM
3) Hydraulic supply OFF
4) Zero point calibration with potentiometer
"PZero" (at TP "
" = 0 V)
5) Hydraulic supply ON – max. system pressure
6) Sensitivity adjustment with potentiometer "
(at TP "
P" = 10 V)
P"
6) Aim of the controller optimization
An optimum between change over characteristic (overshooting tendency with excessive static amplification)
and static accuracy (control error with starting pressure
cut off) is to be achieved (a).
Procedure (see table, page 12)
C: Comparison – command value Q
1) Specification Qcommand = 10 V
2) Limitation of the max. valve opening
(50...100 % opening) by potentiometer "Qmax".
Control of the voltage value at TP "Qmax":
10 V ≙ 100 % Valve opening (with Qcommand = 10 V)
5 V ≙ 50 % Valve opening (with Qcommand = 10 V)
An increase in the P share of the controller increases the
dynamic of the control behavior (b). In case of excessive
gain, the tendency to oscillate increases (c). Limitation of
the I share reduces the static gain. With increasing static
gain, the control deviation is reduced (d).
The D share can be used to influence the transition behavior (minimization of the tendency to oscillate); thus,
the command value is only reached after a longer transition time (f).
12/14
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
Ideal development
a
U
psoll
pist
t
b
U
psoll
Problem:
P share too small
Solution:
➝
Rotate KP against 13 (fine adjustment)
➝
P gain >
DIL 14 ON
DIL 15 OFF
DIL 16 ON
pist
t
c
U
psoll
Problem:
P share too large
Solution:
➝
Rotate KP against 0 (fine adjustment)
➝
use DIL 14 –16 to reduce the
P gain according to the table
pist
t
d
U
pist
psoll
Problem:
P share correct, control deviation too large
Solution:
➝
Increase the I gain share
➝
DIL 11 ON = I share = 0
DIL 12 ON = I share connected
➝
Rotate KI against 13
t
e
U
psoll
Problem:
Time constant of the I share too low
Solution:
➝
Rotate KI against 13 until control deviation and vibration are perfect
➝
If KI = 13 is not sufficient, the P share must also be reduced
pist
t
f
U
psoll
pist
t
Problem:
D share too low
Solution:
➝
Rotate KD against 13
➝
D share >
DIL 8 ON
DIL 9 OFF
DIL 10 OFF
RE 30058/06.12 VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
Adjustment protocol
Created by:
Date:
DIL switch
ON
5
4
ON
3 2 1
ON
As-delivered state
DIL 1
OFF
DIL 2
ON
DIL 3
ON
DIL 4
ON
DIL 5
OFF
DIL 6
OFF
DIL 7
OFF
DIL 8
OFF
DIL 9
OFF
DIL 10
OFF
DIL 11
OFF
DIL 12
OFF
DIL 13
OFF
DIL 14
OFF
DIL 15
ON
DIL 16
OFF
HEX KP
3
HEX KI
9
HEX KD
5
OFF
HEXCODE switch
1
13
Switches
5
9
13/14
14/14
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
35
Unit dimensions (dimensions in mm)
100
24 V= Mains
Plug-in connector
DIN 41612 - F 32
160
Project planning / maintenance instructions / additional information
– The amplifier card may only be unplugged and plugged when de-energized.
– The distance to aerial lines, radios and radar systems must be sufficient (> 1 m).
– Do not lay solenoid and signal lines near power cables.
– For signal lines and solenoid conductors, we recommend using shielded cables.
The cable shield must be connected to the control cabinet extensively and as short as possible.
– The valve solenoid must not be connected to free-wheeling diodes or other protective circuits.
– The cable lengths and cross-sections specified on page 5 must be complied with.
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
RE 30058/06.12
VT-VARAP1-...-2X/...
Hydraulics Bosch Rexroth AG
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
Bosch Rexroth AG Hydraulics
VT-VARAP1-...-2X/... RE 30058/06.12
Notes
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
p/Q closed-loop control amplifier
RE 30134/06.12
Replaces: 12.05
1/12
Type VT-VACAP-500-2X/V0/...
Component series 2X
Table of contents
Contents
Features
Features
Page
1
– Suitable for controlling high-response valves with installed electronics
Ordering code, accessories
2
– Amplifier with additional electronics (daughter card)
Front plate
2
– Analog amplifiers in Europe format for installation in 19" racks
Block diagram with pin assignment
3
– Valve position control with PID behavior
Technical data
4
– Outputs short-circuit-proof
Connection scheme
5
– External shut-off for pressure controller
Additional information
5
Examples
6
– Suitable for pressure sensors (1...6 V, 0...10 V, 4...20 mA),
see data sheet 30271
Functional presentation
7
Special function
7
Setting instructions
8
Controller adjustment
9
Ideal development
10
Adjustment table
11
Unit dimensions
12
Project planning / maintenance instructions /
additional information
12
– Supply for pressure sensors
– Cable break detection for pressure sensor
Notice:
The photo is an example configuration.
The delivered product differs from the figure.
2/12
Bosch Rexroth AG Hydraulics
VT-VACAP-500-2X/V0/... RE 30134/06.12
Ordering code, accessories
VT V
Hydraulic component
(control)
Axis control
A
C
A
P
500 2X V0
=A
Valve type
High-response valve
Option
1 channel
2 channels
no code =
2CH =
2X =
Control
Analog
=A
Function
p/Q control
Customer version
Catalog version
V0 =
=C
=P
500 =
Component series 20 to 29
(20 to 29: Unchanged technical data
and pin assignment)
Serial number for types
Standard variant without valve amplifier function
Preferred types
Amplifier type
Material number
For high-response valves
VT-VACAP-500-20/V0
0811405157
All valve types with installed electronics
VT-VACAP-500-20/V0/2CH
0811405158
Suitable card holder:
– Open card holder VT 3002-1-2X/32F
(see data sheet 29928).
Only for control cabinet installation!
Front plate
1 and 2 with 0811405157
1 only with 0811405158
1
Flow preselection
Zero point flow
2
Q max
–
+
–
+
Adjustment KP
Q=0
KP
Regler
off
KI
Pressure controller off
Adjustment KI
Controller is working
ON
Adjustment KD
KD
Amplification p signal +10 %/–20 %
Pressure zero point ±10 %
Pist
–
+
–
+
Pnull
Test point pactual 0...10 V
Pist
Test point 0 V
0V
RE 30134/06.12 VT-VACAP-500-2X/V0/...
Hydraulics Bosch Rexroth AG
3/12
Block diagram with pin assignment
External p controller
shut off
6…40 V
b10
0…10 V
0V
0…+10 V
0V
z12
z10
z20
b20
DIL4
P soll
Qsoll
Actual value pressure
monitor signal
0…10 V
z18
4…20 mA
z14
1...6 V/0...10 V
b16
0V
b18
External controller
enquiry
24 V/20 mA
Tp4 Tp5
0V
b2
z24
(D)
b8 UAll
(E)
Q=0
Tp
DIL2
“ ON”
DIL5 II
U U
zero
+5 %
b32
24 V
Signal
line
DIL1 pnull
“ ON”
A
M
V
DIL3
Daughter
"Controller off" card
off
UB
24 V
0V
z2
z4
External channel change
Potentiometer supply
External p controller
shut off
6…40 V
z30
10 V
z32
6…40 V
z28
0…10 V
0V
0…+10 V
0V
b12
b14
z22
b22
Message
(no message
> 8 V 20 mA)
+10 V
DC
15 V/100 mA
Basic card
+15 V
0V
–15 V
DC
b2
z6
Supply p sensor
DIL0
No
1
"Controller off"
DIL4
P soll
Qsoll
Actual value pressure
monitor signal (max. 1 mA) 0…10 V
z16
4…20 mA
b24
1...6 V/0...10 V
b26
0V
b28
External controller
enquiry
PID
S5/S6
Qmax
pist
p sensor
p sensor
"Controller off"
PID
Tp4 Tp5
S5/S6
Qmax
0V
b4
DIL2
“ ON”
pist
24 V/20 mA
z26
(D)
b8 UAI (E)
Q=0
Tp
zero
+5 %
DIL5 II
U U
b30
24 V
DIL1 pnull
* Daughter card only attached with 2-channel variant
Signal
line
“ ON”
DIL3
off
A
M
V
"Controller off"
Message
(no message
> 8 V 20 mA)
4/12
Bosch Rexroth AG Hydraulics
VT-VACAP-500-2X/V0/... RE 30134/06.12
Technical data (For applications outside these parameters, please consult us!)
Supply voltage
UB at z2 – b2
Nominal 24 V =
Battery voltage 21...40 V,
Rectified alternating voltage Ueff = 21...28 V
(one-phase, full-wave rectifier)
Smoothing capacitor, separately
at z2 – b2
Recommendation: Capacitor module VT 11110 (see data sheet 30750)
(only necessary if the ripple of UB > 10 %)
Current consumption, max. 0811405157
0811405158
Pressure sensor (1...6 V/0...10 V)
Pressure sensor (4...20 mA)
Pressure sensor supply – V
Pressure command value (0...10) V
160 mA
220 mA
Basic card
b26 – Ref. b28
b24 – Ref. b28
z6 (+15 V)/b8 (0 V)
b12/b14 (0 V)
z12/z10 (0 V)
External controller shut off
z28: 6...40 V =
b10: 6...40 V =
External controller enquiry
Monitor signal pactual
External channel change mode
Flow command value
z26: 24 V =, max. 20 mA
z16: 0...10 V =
z30: 6...40 V =
z22: 0...±10 V =
b22: 0 V
z32: +10 V, max. 10 mA
UAI; b4/b8 (0 V): 0...±10 V
Load RL > 1 kΩ
z24: 24 V =, max. 20 mA
z18: 0...10 V =
Potentiometer supply
Output
Cable: Pressure sensor
Valve
PLC signals
LED displays/channel
Special features
Circuit board format
Plug-in connection
Ambient temperature
Storage temperature range
Weight
Daughter card
b16 – Ref.
b18z14 – Ref. b18
z20: 0...±10 V =
b22: 0 V
UAIl; b6/b8 (0 V): 0...±10 V
Load RL > 1 kΩ
4 x 0.5 mm2 (shielded)
5 x 0.5 mm2 (shielded)
0.5 mm2 (shielded)
Pressure controller OFF
Controller is working
Cable break pressure transducer (both a.-m. LEDs are flashing)
Cable break monitoring for pressure sensor
Test points for important characteristics
External pressure controller shut-off
External channel change mode
Different pressure sensors possible
mm (100 x 160 x approx. 35) / (W x L x H)
Europe format with front panel 7 TE
Connector DIN 41612 – F32
°C 0...+70
°C –20...+70
m 0811405157 – 0.35 kg, 0811405158 – 0.44 kg
RE 30134/06.12 VT-VACAP-500-2X/V0/...
Hydraulics Bosch Rexroth AG
5/12
Connection scheme
Amplifier – Valve
Signal exchange with system control
24 V DC
0V
p/Q card
1 channel
Signal
UB
p/Q control signal
Reference – 0 V
p
Pressure command value
z.B.
4/4 WV – NG10
5/3 WV – NG10
3/2 WV (Cartr.) + Pilot
4/4 WV – NG6
4/3 WV + Pilot
U
Monitor signal pactual
Controller enquiry
Controller shut-off
Channel change mode
Pressure sensor connection: Example channel II
Usup
P
I
Isig
z6
z14
b18
b8
Usup
P
U
0 V/
Usig
z6
b18
b16
b18
b8
Usup
0 V/
Usig
P
U
0 Vsig
z6
b2
b16
b8
Additional information
Applications
The "1-channel p/Q control card" consists of the basic card
in Europe format with DC/DC converter and front plate. With
the "2-channel p/Q control card", this basic card contains a
p/Q daughter card with identical circuit and a joint front plate.
The supply voltage is 24 V =. The voltage of the valve to be
regulated is not supplied via this card.
Input variables for the cards are the valve position command
value, the pressure command value, the actual pressure value and possible control mode signals. The pressure sensors
with voltage interface receive their voltage supply from the
card (z6/z8). At the card, pressure sensors with voltage and
current signal can be connected.
The pressure command value can be specified by means of
a potentiometer. The potentiometers can be supplied from
the card (z32/b12).
For control and comparison, the front plate and the circuit board
comprise test points for the most important characteristics.
The circuit of the "2-channel card" is designed so that the
controllers on basic and daughter card work in a completely
independent manner. In this mode, the card is suitable for
controlling 2 valves with integrated electronics (see example 2, page 6).
An additional channel mode circuit allows for the considerable extension of the possible applications of the described
card (see example 1, page 6).
6/12
Bosch Rexroth AG Hydraulics
VT-VACAP-500-2X/V0/... RE 30134/06.12
Examples
Example 1
Channel mode "joint output"
Pist
Psoll
Daughter card
Qsoll
p
DIL5
Pist
p
I
I
Psoll
DIL0
Basic card
A B
Channel
mode z30
Qsoll
G
DIL5
P T
Example 2
Channel mode "separate outputs"
G
P
Directional valve
G
P
U
Actual value p
A B
A B
G
Directional valve
U
Actual value p
G
P T
P T
Basic card
Daughter card
Pressure
compensator
Pressure
compensator
Qsoll
DIL0
+
Qsoll
Psoll
Psoll
RE 30134/06.12 VT-VACAP-500-2X/V0/...
Hydraulics Bosch Rexroth AG
7/12
Functional presentation
Function and structure of the p/Q controller card are shown
as block diagram (see page 3).
Pressure command value: It is specified by the user in the
form of voltage (0...10 V; b12/b14 and/or z10/z12). You can
do so by means of a potentiometer which can be supplied
by the card (z32/b8).
Actual pressure value: It is optionally recorded by pressure
sensors with voltage interface (1...6 V, 0...10 V) or current
interface (4...20 mA) (which can be switched).
The actual pressure value can be tapped as monitor signal
at z16 and/or z18. The command value is compared to the
actual value. The variation and the differentiated actual value act on a PID controller. The controller output signal acts
on the limiter circuit which influences the position command
value. If the actual pressure value is smaller than the pressure command value, the controller signal is larger than the
specified position command value. It is thus not influenced
by the limiter; there is simple flow control of the valve.
If the pressure command value is reached, the limiter takes
effect according to the actual pressure value so that the input signal for the valve position control is changed so that
pcommand – pactual = 0 is maintained.
Controller characteristic: The PID controller and the
derivative element can be roughly set by means of DIL
switches (printed circuit board) and finely by means of front
plate switches.
Controller display: The controller function is displayed by
means of LED and can be used for switching purposes via
an acknowledgement output.
Line break: Simultaneous flashing of the two yellow LEDs
and the switching of output b30 and/or b32 signalizes
a pressure sensor line break.
Controller shut-off: The controller can be shut off by
means of an external signal (6...40 V =).
Channel selection: Is only possible for the 2-channel card.
Detailed explanation (see below).
Special function "channel selection" of the "2-channel control card"
This special function can be used in all cases in which two
actual pressure values have to act on one control distance
via their two independent controllers. An external mode
signal (z30/6...40 V =) is used to select basic or daughter
DIL 0
ON
ON
OFF
X– without influence
Mode signal z30
H
L
X
p/Q control signal on the control distance. The DIL switch 0
must be ON; otherwise, this special function is blocked. The
control signal of one channel must be inverted (DIL 5).
Basic card I
OFF
ON – out I (b4/b2)
ON – out I (b4/b2)
Daughter card II
ON – out I (b4/b2)
OFF
ON – out II(b6/b8)
DIL 5 I
ON
ON
X
Principle of the channel selection
p/Q output daughter card
Mode signal
No
DIL0
z30
1
p/Q output basic card
Nc
p/Q output
DIL 5 II
OFF
OFF
X
8/12
Bosch Rexroth AG Hydraulics
VT-VACAP-500-2X/V0/... RE 30134/06.12
Setting instructions
A: General instructions
E: Comparison of the position signal
– The measured values generally refer to the ground at the
test point "0 V"
– Shut off the p controller (DIL 4)
– Indication of the direction of rotation for potentiometers:
cw – clockwise ccw – counterclockwise
– Before the commissioning, the position of the setting elements is to be checked according to the transfer condition
(see adjustment table page 11)
– Proceed in the order b) to f) (page 10).
B: Mode settings
DIL no. Status
0
ON
OFF
1
2
ON
OFF
ON
OFF
3
Function
Both controllers act on output 1
Controller 1 and 2 act on output 1
and/or 2, irrespective of each other
Pressure sensor 1...6 V/0...10 V
Pressure sensor 4...20 mA
Actual p value amplification
psys1) ≙ ~ pnom2)
Actual p value amplification
psys ≙ ~ 0.5 • pnom
ON
OFF
ON
OFF
Cable break detection active
Cable break detection inactive
4
p controller active
p controller shut off,
only the Q signal is analyzed
5
ON
p/Q output signal not inverted
OFF
p/Q output signal inverted
1) p
sys = System pressure
2) p
nom = Nominal sensor pressure
C: Pressure sensor comparison
– Set the sensor type (DIL 1) and the gain factor (DIL 2)
– The zero point comparison is effected using the potentiometer pzero in order to achieve 0 V (±10 mV) at the signal input with pressure-relieved pressure transducer
– The sensitivity is aligned using the potentiometer pactual at
system pressure (+10 % / –20 %).
D: Flow zero point
The zero position of the valve is set using the potentiometer Qzero (±10 %). Due to the valve amplifier integrated in the
valve, direct adjustment at the amplifier is not intended.
– Set the command value amplification using the potentiometer Qmax..
F: Optimization of the control characteristic
DIL no. Status
6
ON
OFF
7
ON
OFF
8
ON
Function
D Pressure
build-up
Pressure
reduction
Share high
9
10
11
12
13
Share medium
Share low
I Share = 0
Share available
P Reduced pressure reduction
ON
ON
ON
ON
ON
normal
reduced 1)
normal
reduced 1)
(9, 10 = OFF)
(8, 10 = OFF)
(8, 9 = OFF)
(12 = OFF)
(11 = OFF)
Valve opening in
case of pressure
reduction
< approx.15 %
OFF
ineffective
(16 = ON/15 = OFF)
14
ON
Share low
15
ON
Share medium (14, 16 = OFF)
16
ON
Share high
(14, 15 = OFF)
1) With DIL 6 and 7 = OFF, DIL 8 is ineffective
G: Test points
The test points of the card may only be loaded with
a RL > 10 kΩ. in case of overload, the function of the control is impaired and/or the card is destroyed. The test points
are located on the front plate and laterally on the printed circuit board.
Basic card and daughter card have separate test points
each, however the identical reference ground.
RE 30134/06.12 VT-VACAP-500-2X/V0/...
Hydraulics Bosch Rexroth AG
9/12
Controller adjustment
The P, I and D shares of the closed-loop control amplifier
are to be optimized according to the properties of the control
distance, the disturbance variables and the static and dynamic requirements on the control result.
1) Pressure controller ON – DIL 4 ON
2) Connection of an oscilloscope at the test point "pactual"
3) Usefully connection of a 2nd oscilloscope channel at the
terminals "pcommand"
4) DIL 6 and DIL 7 serve to compensate dynamic differences in the pressure build-up and reduction in the system
DIL 6 ON = Normal application
OFF = Special application
DIL 7 ON = Normal application
OFF = Special application
5) DIL 13 reduces the pressure reduction by means of
a max. valve opening < approx. 15 %
ON = Special application
OFF = Normal application
6) Aim of the controller optimization
An optimum between change over characteristic (overshooting tendency with excessive static amplification) and static
accuracy (control error with starting pressure cut off) is to be
achieved (a).
Procedure (see table, page 11):
An increase in the P share of the controller increases the
dynamic of the control behavior (b). In case of excessive
gain, the tendency to oscillate increases (c).
Limitation of the I share reduces the static gain. With increasing static gain, the control deviation is reduced (d). The
D share can be used to influence the transition behavior
(minimization of the tendency to oscillate); thus, the command value is only reached after a longer transition time (f).
10/12
Bosch Rexroth AG Hydraulics
VT-VACAP-500-2X/V0/... RE 30134/06.12
Ideal development
a
U
P soll
P ist
t
Problem:
P share too small
b
U
P soll
Solution:
→ Rotate Kp against F (fine adjustment)
→ P gain >
P ist
t
DIL 14
ON
DIL 15
OFF
DIL 16
ON
Problem:
P share too large
c
U
P soll
Solution:
→ Rotate Kp against 0 (fine adjustment)
→ use DIL 14–16 to reduce the P gain according to the table
P ist
t
d
U
P ist
P soll
t
Problem:
P share correct
Control deviation too large
Solution:
→ Increase the I gain share
DIL 11 ON = I share = 0
DIL 12 ON = I share connected
→ Rotate Ki against F
Problem:
Time constant of the I share too low
e
U
P soll
Solution:
→ Rotate Ki against F until control deviation and vibration are perfect
→ If Ki = F is not sufficient, the P share must also be reduced
P ist
t
Problem:
D share too low
f
U
P soll
Solution:
→ Rotate KD against F
→ D share >
P ist
t
DIL 8
ON
DIL 9
OFF
DIL 10
OFF
RE 30134/06.12 VT-VACAP-500-2X/V0/...
Hydraulics Bosch Rexroth AG
Adjustment table
DIL 16...0
TP 4
TP 5
TP 4: UA
TP 5: 0 V
* Daughter card
Basic card
Set by
Rexroth
Date
As-delivered state
Date
As-delivered state
DIL 0
OFF
DIL 0
OFF
DIL 1
OFF
DIL 1
OFF
DIL 2
ON
DIL 2
ON
DIL 3
ON
DIL 3
ON
DIL 4
ON
DIL 4
ON
DIL 5
OFF
DIL 5
OFF
DIL 6
OFF
DIL 6
OFF
OFF
DIL 7
OFF
DIL 8
OFF
DIL 9
DIL 10
OFF
DIL 10
OFF
DIL 11
OFF
DIL 11
OFF
DIL 12
OFF
DIL 12
OFF
DIL 13
OFF
DIL 13
OFF
DIL 14
OFF
DIL 14
OFF
DIL 15
ON
DIL 15
ON
DIL 16
OFF
DIL 16
OFF
HEX KP
B
HEX KP
3
1
HEX KI
D
HEX KD
DIL 9
HEX KI
HEX KD
HEX code
DIL 8
HEX code
DIL 7
DIL switch
Rexroth
DIL switch
Set by
ON
OFF
OFF
9
5
* Only with 2-channel variant
DIL switch
HEXCODE switch
1
ON
5
4
ON
3 2 1
ON
OFF
D
5
9
11/12
12/12
Bosch Rexroth AG Hydraulics
VT-VACAP-500-2X/V0/... RE 30134/06.12
35
Unit dimensions (dimensions in mm)
100
24 V= Mains
Plug-in connector
DIN 41612 - F 32
160
Project planning / maintenance instructions / additional information
– The amplifier card may only be unplugged and plugged when de-energized.
– The distance to aerial lines, radios and radar systems must be sufficient (> 1 m).
– Do not lay solenoid and signal lines near power cables.
– For signal lines and solenoid conductors, we recommend using shielded cables.
The cable shield must be connected to the control cabinet extensively and as short as possible.
– The valve solenoid must not be connected to free-wheeling diodes or other protective circuits.
– The cable lengths and cross-sections specified on page 4 must be complied with.
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
Δp/Q controller
RE 30136/07.12
Replaces: 05.04
1/16
Type VT-VACAF
Component series 1X
Table of contents
Contents
Features
Page
– Suitable for controlling high-response valves
Features
1
– Amplifier with additional electronics (daughter card)
Ordering code, accessories
2
– Analog amplifiers in Europe format for installation
in 19 " racks
Front plate
2
Block diagram with pin assignment
3
Wiring diagram with valve amplifier card
4
Wiring diagram – Valve with installed electronics
5
Technical data
6
Functional principle
7
Additional information
7
Examples
8
Function
9
Settings DIL switch
10
Commissioning and adjustment
12
Adjustment protocol
15
Device dimensions
16
Project planning / maintenance instructions /
additional information
16
– Pressure differential controller (force controller) with
PID behavior
– Short-circuit-proof outputs
– External shut-off for pressure controller
– Monitor signal for controller
– Separate acceleration and braking ramp
– Ramps can be separately adjusted and switched off
– Adjustable area adjustment for cylinder
– Suitable for pressure sensors (0...10 V, 4...20 mA),
see data sheet 30271
– Supply for pressure sensors
– Cable break detection for pressure sensor
Notice:
The photo is an example configuration.
The delivered product differs from the figure.
2/16
Bosch Rexroth AG Hydraulics
VT-VACAF RE 30136/07.12
Ordering code, accessories
VT V
Hydraulic component
(control)
Axis control
A
C
A
F
500 10 V0
=A
Valve type
High-response valve
1X =
=C
Control
Analog
=A
Function
Δp/Q control
Customer version
Catalog version
V0 =
Component series 10 to 19
(10 to 19: Unchanged technical data
and pin assignment)
Serial number for types
500 = Standard variant without valve amplifier function
=F
Preferred types
Amplifier type
Material number
VT-VACAF-500-10/V0
0811405147
Suitable card holder:
– Open card holder VT 3002-1-2X/32F
(see data sheet 29928).
Only for control cabinet installation.
Front plate
green Controller is working
green UB
ON
yellow Controller not active
UB
QCommand gain
Ramp A
TP
OFF
QCommand
Zero point Np
Pressure
sensor B
A
TP
Valve
TP
pactual
Zero point Np
Gain
–
+
B
–
+
TP
pdiff
Pdiff
Δp controller OFF
KP
Q max
KP
Hex
Ramp
off
Q soll
zero
B
Ramp B
KI
Hex
KI
TP
pcommand
Hex
KD
TP
pactual
valve
Psoll
KD
Pist
Pnull –
A
Zero point Np
+
OFF
Pressure sensor A
Gain
B
Area adjustment
coarse
off
Area adjustment fine
0V
TP
0V
0V
0V
+UB
UB +24V
Command
value Q
p controller
OFF
Ramp A
OFF
Ramp B
OFF
Command
value pDiff
6…40 V=
0V
8…40 V=
+ 10 V
8…40 V=
0V
+ 10 V
0V
0…10 V
Pressure sensor A
4…20 mA
Pressure sensor A
0V
0…10 V
Pressure sensor B
4…20 mA
Pressure sensor B
Control zero 0 V
Power zero
Inputs
b10
z20
z26
b20
z22
z12
z10
b28
b26
b24
b30
b18
b16
z14
z30
z28
b12
b14
b8
b4
b2
z4
z2
+
–
+
–
+
–
DIL4
+
– Ramp A
OFF
DIL2
DIL0
200 Ω
200 Ω
DC
DIL3
DC
+10 V
OFF
<21 V
1
UB ON/UB
Q+
Q–
Tp"pAB"
TV
– –
+
OFF
TI
KP
DIL6-10 KD DIL11-13 KP
Gain Qsoll
50...100%
Tp"psoll diff"
Tp"pA"
Tp"Qsoll"
Tα,δ =0
+5 %
Np DG A
γ
δ
Gain DG A
50...100%
+5 %
Np DG B
Σ
Tp"pB"
1:1-1:4
Area adjustment
0...0,25%
Gain DG B
50...100%
Ramp B
Tα,β =0
+10 V
α β
DIL1
1
+24 V
+10 V
–10 V
+15 V
–15 V
< 21 V
24 V
Δ P/Q
ON
24 V=
24 V=
DIL5
ON/OFF
+10 V
Valve
Np
+5 %
1
Pressure controller
KI DIL15,16
b6
0V
24 V
0 V (E)
+ 10 V
Monitor signal
p controller
0V
External
controller enquiry
24 V
Pressure sensor
0 V Control zero
+10 V/10 mA
10 V/10 mA
+15 V/100 mA
15 V/100 mA
+ 10 V (Q)
Valve output
b8
z16
z24
b22
z32
b32
z6
z8
b12
b14
Outputs
RE 30136/07.12 VT-VACAF
Hydraulics Bosch Rexroth AG
Block diagram with pin assignment
3/16
SPS
SPS
Command value pDiff
Command
value Qcommand
Ramp OFF
Ramp OFF
p controller OFF
Pressure sensor
External
controller enquiry
Monitor signal
p controller
z26
b20
z20
z10
z12
10...+10 V
Ref–0 V
10...+10 V
Ref–0 V
z22
6…40 V=
B 6…40 V=
A
b22
z24
b10
0V
24 V
z16
6…40 V=
24 V
0V
+ 10 V
or
p
B
I
p
U
p
or
A
I
p
100 mA
z8
Valve
24 V
100 mA
z6
b32 10 mA
z2
Enable
0V
z22
15 V
+15 V
10 V
+10 V
z20
b8
z32 10 mA
b20
b6
L –0 V
b8
b6
U
U
b22
z30
b24
b30
b26
z30
b28
b30
s
s
1 2
St –0 V
Neutral point 0 V
1 2 3 4
1 2 3 4
Bosch Rexroth AG Hydraulics
U
z4
Δ p/Q
z2
b24
b30
St –0 V
z14
z30
+24V
b2
b26
b28
b14
b12
z28
b4
b16
b18
b2
z16
8,5…40 V=
4/16
VT-VACAF RE 30136/07.12
Wiring diagram with valve amplifier card
z28
z4
b4
SPS
SPS
z26
b20
z20
z10
z12
B 6…40 V=
10...+10 V
Ref–0 V
10...+10 V
Ref–0 V
Command value pDiff
Command
value Qcommand
Ramp OFF
z22
6…40 V=
A
Ramp OFF
b22
z24
b10
0V
24 V
6…40 V=
24 V
0V
p controller OFF
Pressure sensor
External
controller enquiry
z16
U
p
or
B
I
z4
Δ p/Q
p
z14
z30
+ 10 V
U
p
z2
or
A
I
p
b24
b30
100 mA
100 mA
z6
z8
b32 10 mA
z32 10 mA
b8
b6
2.5 AF
+24V
Neutral point 0 V
b2
b26
b28
Monitor signal p controller
b14
b12
z28
b4
b16
b18
Actual value valves
Ref–0 V + 10 V
15 V
+15 V
10 V
+10 V
A
B
C
D
E
F
U s
U s
RE 30136/07.12 VT-VACAF
Hydraulics Bosch Rexroth AG
Wiring diagram – Valve with installed electronics
5/16
6/16
Bosch Rexroth AG Hydraulics
VT-VACAF RE 30136/07.12
Technical data (For applications outside these parameters, please consult us!)
Supply voltage
UB at z2 – b2
Nominal 24 V =
Battery voltage 21...40 V,
Rectified alternating voltage Ueff = 21...28 V
(one-phase, full-wave rectifier)
Smoothing capacitor, separately
at z2 – b2
Recommendation: Capacitor module VT 11110 (see data sheet 30750)
(only necessary if the ripple of UB > 10 %)
Current consumption, max.
Command value Q
Command value pdiff
Actual value from the pressure sensor
mA 250
b20: 0...±10 V
Differential amplifier
z20: 0...±10 V
(Ri = 100 kΩ )
z10: 0...±10 V
Differential amplifier
z12: 0 V
A b26: 0...+10 V
Differential amplifier
b28: 0 V
b24:
b30:
4...20 mA
B b16: 0...+10 V
Differential amplifier
b18: 0 V
b14:
b30:
4...20 mA
z6: +15 V, max. 100 mA
z8: –15 V, max. 100 mA
b10: 6...40 V =
z24: 24 V/0.1 A max., if controller is not active
Supply ±10 V from b32, z32 (10 mA) or external signal source
z16: ±10 V
}
}
}
}
Pressure sensor supply
Pressure controller OFF
External controller enquiry
Signal source
Monitor signal Factual
Error pressure sensor
(cable break, signal lines)
Ramp times
Ramp OFF
Area adjustment cylinder
LED displays
Format of the printed circuit board
b22: No error: +UB; max. 100 mA
Error: 0 V
: LED "Ramp A OFF" and
"Ramp B OFF" flash
Min. 350 ms (1)
16 steps
350 ms/step
Max. 5.6 s (16)
A z22: 8...40 V =
B z26: 8...40 V =
Min. 1:1 (1)
16 steps
Max. 1:4 (16)
red:
Error UB
red:
Ramp A OFF
red:
Ramp B OFF
green/yellow:
green: Controller active
yellow: Controller not active
off: Controller OFF
}
}
mm (100 x 160 x approx. 35) / (W x L x H)
Europe format with front plate 7 TE
Connector DIN 41612 – F32
°C 0...+70
°C –20...+70
m 0.44 kg
Plug-in connection
Ambient temperature
Storage temperature range
Weight
Notice:
Power zero b2 and control zero b12 or b14 or z28 must be separately led to the central ground (neutral point).
Hydraulics Bosch Rexroth AG
RE 30136/07.12 VT-VACAF
7/16
Functional principle
Force control
m
p
p
U
B
U
A
Δ p soll
Qsoll
Additional information
Applications
As opposed to p/Q control, pressure measurement in the A
and B line of a hydraulic actuator by means of the "Pressure
differential controller" printed circuit board can be used to allow for Δp/Q control of the actuator.
Consequently, this control structure is used everywhere
where you don't only have to control the pressure in one direction of motion of the actuator against a constant pressure
but where there is also pressure control against a changing
pressure, i.e. in all cases, in which force control is necessary.
The actual value adjustment allows for the connection of
pressure sensors with 0...10 V and 4...20 mA output signal.
The command value ramps allow for the design of command
value steps of Δpcommand as ramp function. The error monitoring logic detects cable break of the signal lines of the sensors and errors in the voltage supply. The pressure control
circuit can also be switched off externally (flow control).
To control the actuator, this printed circuit board is to be
coupled with a valve amplifier card or a valve with installed electronics.
8/16
Bosch Rexroth AG Hydraulics
VT-VACAF RE 30136/07.12
Examples
Example 1
Welding machine
Welded seam
p
p
U
U
G
Δ p soll
Qsoll
Δ p/Q
Example 2
Vehicle twisting test stand
p
U
p
U
G
Δ p soll
Δ p/Q
P
Qsoll
Hydraulics Bosch Rexroth AG
RE 30136/07.12 VT-VACAF
9/16
Function
Input variables are the differential pressure Δp and flow Q
command values. As actual values, pressure differential and
valve spool path are fed back.
The Δp/Q controller takes effect:
a) As long as Δpcommand > Δpactual like a flow control, i.e. the
pressure control does not yet take effect;
The command value Q corresponds to the spool path as
long as the pressure control does not take effect, yet, i.e.
Δpcommand > Δpactual or if the pressure controller is switched off.
The command value Q may range between UE = 0...±10 V.
b) If Δpcommand = Δpactual, the pressure control takes effect,
i.e. a limiter superimposes the command value Q.
Functional examples
Direction
Qcommand
pdiff. command
+5.0 V
Track traveling
Force control
+3.5 V
with 50 % vmax.
After track traveling to 35 %
of pdiff. max.
+7.5 V
–2.0 V
with 75 % vmax.
Not possible
–3.3 V
–4.8 V
with 33 % vmax.
After track traveling to 48 %
of pdiff. max.
–10.0 V
+8.0 V
with vmax.
Not possible
↓
Direction
A command value of at least ±0.3 V must be specified!
The numerical values listed in the table are examples,
the signs of the values are decisive.
10/16
Bosch Rexroth AG Hydraulics
VT-VACAF RE 30136/07.12
Settings DIL switch
DIL no. Status
0
ON
OFF
4
5
ON
OFF
ON
OFF
ON/OFF
Cable break detection p sensor ON
Cable break detection OFF
External controller shut-off possible
External controller shut-off not possible
Inversion of the hydraulic direction of action
→ +QCommand must extend the cylinder
6
7
8
9
10
11
12
13
14
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
15
OFF
ON
16
OFF
D share
3
4...20 mA pressure sensors
0...10 V pressure sensors
External ramp control possible
+ pdiff. command via ramp
P share
2
A
ON
OFF
ON
OFF
I share
1
Function
External ramp control possible
+ pdiff. command via ramp
B
Switch combinations,
see table 1
Switch combinations,
see table 2
Reduced pressure decrease with pdiff. actual > pdiff. command
Valve opening max. 20 %
No reduced pressure reduction
Switch combinations, see table 3
Ramps
α
β
γ
δ
DIL
5 ........ 0
6 . . . . . . 10 11 . . . . . . . .16
DIL
Without function
OFF
ON
OFF
ON
Hydraulics Bosch Rexroth AG
RE 30136/07.12 VT-VACAF
Table 1
Using the DIL switches 6 ... 10, the setting of the hex switch KD (front
plate) can be reduced.
The setting can be reduced in a direction-dependent form.
Step 1 is the lowest, step 8 the highest reduction.
KD
DIL 6 DIL 7 DIL 8
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
ON
ON
OFF
OFF
ON
OFF
ON
ON
ON
OFF
ON
ON
ON
1 OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
2 ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
3 OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
4 ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
5 OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
6 ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
7 OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
8 ON
ON
ON
ON
ON
ON
ON
ON
ON
Direction 1 ≙ force reduction
Direction 2 ≙ force build-up
DIL 9
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
DIL 10
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
ON
OFF
ON
Effect
No influence on the
hex switch KD
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
Direction 1
Direction 2
Direction 1 + 2
11/16
12/16
Bosch Rexroth AG Hydraulics
VT-VACAF RE 30136/07.12
Table 2
DIL 11 DIL 12 DIL 13 Effect
OFF
OFF
OFF
No gain reduction to hex
switch KP
OFF
OFF
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
Low gain
Medium gain
High gain
Forbidden
Table 3
DIL 15 DIL 16 Effect
OFF
OFF
No influence on the hex switch KI
OFF
ON
ON
ON
ON
OFF
I share = 0
I max. (≙ KI = 16) + KI current
Commissioning and adjustment
General notes:
Setting during the commissioning is effected using potentiometers and HEXCODE switches on the front plate as well
as using DIL switches on the printed circuit board.
Test points for voltage measurements as well as LED displays are located on the front plate. The measured values
generally refer to the test point 0 V. The test points may only
be loaded with measuring devices RL ≧ 10 kΩ.
Overload impairs the control function and/or the printed circuit board is damaged. Before the commissioning, the basic
settings of the as-delivered state are to be checked. In the
card adjustment, proceed in the order of the points shown
(see page 13).
Hydraulics Bosch Rexroth AG
RE 30136/07.12 VT-VACAF
Verification of the
connections
Default setting controller
parameters
– Electrical
According to connection diagram, page 4 and/or 5
– Hydraulic
Pressure sensor A for piston chamber
Pressure sensor B for annulus area.
– According to the table, page 15,
column as-delivered state.
– Carry out the settings according to the table, page 10.
Mode settings
DIL 0...5
– Set an area ratio 1:1.
Pressure sensor
adjustment
– System depressurized: Zero point adjustment
→ Potentiometer pzero → TPP actual = 0 V.
– Max. system pressure: Gain adjustment
→ TPP actual = 10 V.
→ Potentiometer
Setting of the cylinder
area ratio
Adjustment Qmax.
Valve zero point adjustment
Controller adjustment
– Set the hex switch to the area ratio of
the cylinder; potentiometer to ccw.
This potentiometer is used for the fine tuning during
the controller adjustment.
– Specification of the max. command value (e. g. 7 V)
→ Potentiometer
Qmax. → Adjustment to
10 V at TP-QCommand.
– Specification QCommand = 0 V → The forces at
the cylinder must be balanced (i.e. pressure
ratio pK:pR must correspond to the ratio AK:AR).
– Working in the control loop
→ Specification of command value steps pdiff.
(e. g. 30 % → 70 % and –20 % → –60 %)
→ Comparison of command and actual value
(see table, page 14)
→ Correction/adjustment of the parameters
according to tables 1 to 3
→ Fine correction area ratio.
13/16
14/16
Bosch Rexroth AG Hydraulics
Ideal development
(only a square is shown)
a
U
P soll
P ist
t
b
U
P soll
P ist
Problem:
P share too low
Solution:
→ Rotate Kp against 16
(fine adjustment)
→ P gain >
see table 2, DIL 11–13
t
c
U
P soll
P ist
Problem:
P share too large
Solution:
→ Rotate Kp against 1
(fine adjustment)
→ Use DIL 11–13
to reduce the P gain
according to table 2
t
d
U
P ist
P soll
Problem:
P share correct,
control deviation too large
Solution:
→ Increase the I gain share
according to table 3
→ Rotate KI against 16
t
e
U
P soll
P ist
Problem:
Time constant of the I share too low
Solution:
→ Rotate KI against 16 until control
deviation and vibration are perfect
→ if KI = 16 is not sufficient,
the P share must also be
reduced, see table 2
t
f
U
P soll
P ist
t
Problem:
D share too low
Solution:
→ Rotate KD against 16
→ D share >, see table 1
(DIL 6–10)
VT-VACAF RE 30136/07.12
Hydraulics Bosch Rexroth AG
RE 30136/07.12 VT-VACAF
Adjustment protocol
Created by
Date
Switches
As-delivered state
DIL 0
ON
DIL 1
ON
DIL 2
ON
DIL 3
ON
DIL 4
OFF
DIL 5
ON
DIL 6
OFF
DIL 7
OFF
DIL 8
OFF
DIL 9
OFF
DIL 10
OFF
DIL 11
OFF
DIL 12
ON
DIL 13
OFF
DIL 14
ON
DIL 15
OFF
DIL 16
ON
HEX α
3
HEX β
3
HEX γ
3
HEX δ
3
HEX KP
1
HEX KI
1
HEX KD
1
↓
15/16
16/16
VT-VACAF RE 30136/07.12
Bosch Rexroth AG Hydraulics
35
Device dimensions (dimensions in mm)
Connector
100
24 V= Mains
DIN 41612 - F 32
160
Project planning / maintenance instructions / additional information
– The amplifier card may only be unplugged and plugged when de-energized.
– The distance to aerial lines, radios and radar systems must be sufficient (> 1 m).
– Do not lay solenoid and signal lines near power cables.
– For signal lines and solenoid conductors, we recommend using shielded cables.
The cable shield must be connected to the control cabinet extensively and as short as possible.
– The valve solenoid must not be connected to free-wheeling diodes or other protection circuits.
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
[email protected]
www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties without its consent.
The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not
release the user from the obligation of own judgment and verification. It
must be remembered that our products are subject to a natural process
of wear and aging.
Digital axis control
Type VT-HNC100...3X
Operating Instructions
RE 30139-B/10.11
Replaces: 04.10
English
The data specified below only serve to describe
the product. Any information with regard to
use only refers to application examples and
recommendations. Data available in catalogs are
no guaranteed characteristics. The information
given does not exempt the user from making own
evaluations and tests. Our products are subject to
a natural process of wear and aging.
© This document, as well as the data,
specifications and other information set forth in it
are the exclusive property of Bosch Rexroth AG.
It may not be reproduced or given to third parties
without our consent.
The cover shows a sample configuration. The
product supplied may therefore differ from the
photo shown.
The original operating instructions were prepared
in German.
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
3/48
Inhalt
Inhalt
1 About this document.......................................................................................4
1.1 Validity of the documentation.....................................................................4
1.2 Additional documentation..........................................................................4
1.3 Illustration of information ...........................................................................5
2 Safety instructions..........................................................................................7
2.1 General information on this chapter...........................................................7
2.2 Intended use..............................................................................................7
2.3 Qualification of personnel..........................................................................8
2.4 General safety instructions........................................................................8
2.5 Product- and technology-related safety instructions.................................. 9
2.6 Personal safety equipment......................................................................10
3 Scope of delivery...........................................................................................10
4 Information on this product..........................................................................11
4.1 Performance description..........................................................................11
4.2 Product description..................................................................................11
4.3 Product identification...............................................................................13
4.4 Pin assignments......................................................................................14
5 Transport and storage...................................................................................19
5.1 VT-HNC100...3X storage.........................................................................19
6Assembly........................................................................................................20
6.1 Installation conditions..............................................................................20
6.2 Recommended accessories....................................................................21
6.3 VT-HNC100...3X assembly......................................................................21
6.4 VT-HNC100...3X mechanical assembly..................................................23
7Commissioning..............................................................................................37
7.1 First commissioning.................................................................................37
7.2 Commissioning software WIN-PED® 6 and
WIN-PED® 7............................................................................................37
7.3 Installation requirements..........................................................................38
8Operation........................................................................................................41
8.1 Software description................................................................................41
9 Maintenance and repair.................................................................................42
9.1 Cleaning and care....................................................................................42
9.2Maintenance............................................................................................42
9.3Repair......................................................................................................42
10 Disassembly and replacement.....................................................................43
10.1Preparing for disassembly.......................................................................43
10.2Disassembling the digital axis control......................................................43
10.3Preparing the components for storage/further use.................................. 43
11Disposal..........................................................................................................44
11.1Environmental protection.........................................................................44
11.2Return to Bosch Rexroth.........................................................................44
11.3Packagings..............................................................................................44
11.4Materials used.........................................................................................44
11.5Recycling.................................................................................................44
12 Extension and conversion............................................................................45
13Troubleshooting............................................................................................45
13.1How to proceed with troubleshooting.......................................................45
14 Technical data................................................................................................46
15Appendix........................................................................................................ 47
15.1Address directory.....................................................................................47
4/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
About this document
1
About this document
1.1 Validity of the documentation
This documentation is applicable for the digital axis controls
VT-HNC100-...-3X/C..., VT-HNC100-...-3X/P..., VT-HNC100-...-3X/N... and
VT-HNC100-...-3X/E... of the VT-HNC100 product family of the 3X/... series. .
For the precise identification of the products see chapter 4.3 “Identification of the
product” on page 13.
This documentation is intended for assembly fitters, operators and service
technicians and plant operators.
This documentation contains important information on the safe and appropriate
assembly, transport, electrical connection, commissioning, operation, use,
maintenance, disassembly and simple troubleshooting of the product.
ff You should read this documentation thoroughly, and in particular the chapter
“Safety instructions” before working with the product.
1.2 Additional documentation
Documentations marked with the book symbol
must be available for you
before handling the product and must be complied with:
Table 1:
Title
Document number
Document type
Digital axis control
VT-HNC100...3X
RE 30139
Technical data sheet
Available on the
Internet under www.
boschrexroth.
com
Declaration on the environmental
compatibility for EMC, climate and
mechanical load
RE 30139-U
boschrexroth.
com
Online help in the commissioning
software
WIN-PED® 6 and/or WIN-PED® 7
Available on the
Internet under www.
boschrexroth.
com/hnc100
“First steps” towards WIN-PED
General product information on
hydraulic products
Environmental
statement
Available on the
Internet under www.
Available on the
Internet under www.
RE 07008
boschrexroth.
com/hnc100
Available on the
Internet under www.
boschrexroth.
com
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
5/48
About this document
1.3 Illustration of information
Consistent safety notes, symbols, terms and abbreviations are used so that you
can quickly and safely work with your product using this documentation. For a
better understanding, they are explained in the following sections.
1.3.1 Safety instructions
In this documentation, safety instructions are indicated whenever sequences of
operations are explained which bear the risk of injury or damage to property. The
measures described for preventing these hazards must be observed.
Safety instructions are set out as follows:
Signal word
Type of risk
Consequences in case of non-compliance
ff Precaution
••
••
••
••
••
Warning signs: Draws attention to the hazard
Signal word: Identifies the degree of hazard
Type of risk: Specifies the type or source of the hazard
Consequences: Describes the consequences of non-compliance
Precautions: Specifies how the hazard can be prevented
Table 2: Risk classes according to ANSI Z535.6-2006
Warning sign, signal word
Meaning
DANGER!
Indicates a dangerous situation which may cause death
or severe personal injuries if not avoided
WARNING
Indicates a dangerous situation which may cause death
or severe personal injuries if not avoided
CAUTION
Indicates a dangerous situation which may cause minor
or medium personal injuries if not avoided
NOTE
Damage to property: The product or the environment
could be damaged.
1.3.2 Symbols
The following symbols indicate notes which are not safety-relevant but increase
the understanding of the documentation.
Table 3: Meaning of the symbols
Symbol
Meaning
If this information is not observed, the product cannot be used and/
or operated optimally.
ff abc
Individual, self-dependent step
6/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
About this document
1.3.3 Denominations
The following denominations are used in this documentation:
Table 4: Denominations
Denomination
Meaning
VT-HNC100...3X
Digital axis control
WIN-PED®
Operating software WIN-PED® 6 or WIN-PED® 7 for
VT-HNC100...3X
RE xxxx
Rexroth document in English language
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Table 5: Abbreviations
Abbreviation
Meaning
CAN
Controller AREA Network
CPU
Central Processing Unit
I/O
Input/Output
EMC
Electromagnetic Compatibility
FU
Frequency converter
HMI
Human Machine Interface
HNC
Hydraulic Numerical Control
L
Active Link
NS
Network Status
OK
HNC ready for operation
PC
Personal Computer
RE
Rexroth data sheet in English language
S
Status LED
PLC
Programmable logic controller
USB
Universal Serial Bus
PELV
Protective Extra Low Voltage
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
7/48
Safety instructions
2
Safety instructions
2.1 General information on this chapter
The VT-HNC100...3X axis control has been manufactured according to the
accepted rules of current technology. However, there is still the risk of injury and
damage to property if you do not observe this chapter and the safety instructions
in this documentation.
ff Read these instructions completely and thoroughly before working with the
product.
ff Keep this documentation in a location where it is accessible to all users at all
times.
ff Always include the required documentation when you pass the
VT-HNC100...3X on to third parties.
ff Only operate the VT-HNC100...3X in a technically immaculate condition
and as intended, in a safety- and risk-conscious manner, considering these
instructions.
ff In case of failures impairing the safety and modifications to the operating
behavior, shut down the VT-HNC100...3X immediately and report the failures
to the responsible personnel.
2.2 Intended use
The VT-HNC100...3X is an electric assembly.
You may use the product as follows:
A VT-HNC100...3X is intended exclusively for integration into a machine or
system or to be assembled with other components to form a machine or system.
The product may be commissioned only if it is integrated in the machine/system
for which it is designed. Observe the operating conditions and performance limits
specified in the technical data.
The VT-HNC100...3X is used for the open-loop and closed-loop control of
position, pressure, velocity, differential pressure and optional synchronous
operation of maximal four electro-hydraulic axes. When using the unit, you
moreover need superordinate control logics with corresponding I/O components
that in connection with the VT-HNC100...3X are responsible for the holistic control
of the machine's motion sequence and also its monitoring as regards safety.
The VT-HNC100...3X must not be used in explosive environments.
The VT-HNC100...3X is designed for professional and not for private use.
Intended use includes having read and understood this documentation, especially
the chapter 2 “Safety instructions”.
Any use deviating from the intended use is not intended and thus not admissible.
Bosch Rexroth AG does not assume any liability for damages caused by not
intended use. The user assumes all risks involved with not intended use.
Not intended us of the product includes:
•• Using the digital axis control outside the specified performance limits and
operating conditions and in particular the specified environmental conditions;
•• Using the digital axis control as safety-related part of controls in the sense of
DIN EN ISO 13849. Functional safety must be implemented using appropriate
additional components.
8/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Safety instructions
2.3 Qualification of personnel
The activities described in this documentation require trained knowledge of
electric installation, control technology, programming and hydraulics as well as
the knowledge of the appropriate technical terms. In order to ensure safe use,
these activities may only be carried out by qualified technical personnel or an
instructed person under the direction and supervision of a qualified person.
Qualified personnel are those who can recognize potential hazards and apply the
appropriate safety measures due to their professional training, knowledge and
experience, as well as their understanding of the relevant conditions pertaining
to the work to be undertaken. Qualified personnel must observe the rules/laws
relevant to the specific subject area.
The operation of the VT-HNC100...3X digital axis control requires the safe
handling with the PC program WIN-PED®. A description of the handling of the
program WIN-PED® as well as first steps for operation are available on the
Internet under http://www.boschrexroth.com/hnc100.
We recommend the participation in a product-specific training of Bosch Rexroth.
Rexroth offers training support in specific fields. An overview of the training
contents are available on the Internet under:
http://www.boschrexroth.de/didactic. Or contact your online
support by email under [email protected]
2.4 General safety instructions
•• Observe the applied provisions for the prevention of accidents and for
environmental protection.
•• Observe the safety regulations and provisions of the country where the product
is implemented/used.
•• Exclusively use Rexroth products in good technical order and condition.
•• Observe all notes on the product.
•• Persons who assemble, operate, disassemble or maintain Rexroth products
must not consume any alcohol, drugs or pharmaceuticals that may affect their
ability to respond.
•• Only use accessories and spare parts authorized by the manufacturer.
•• Comply with the technical data and ambient conditions indicated in the product
documentation.
•• The installation or use of inappropriate products in safety-relevant applications
could result in uncontrolled operating conditions when being used which in turn
could cause injuries and/or damages to property. Therefore please only use
a product for safety-relevant applications if this use is expressly specified and
permitted in the documentation of the product.
•• Do not commission the product until you can be sure that the end product
(for example a machine or system) where the Rexroth product is installed
complies with the country-specific provisions, safety regulations and application
standards.
•• Please observe the safety-relevant information and risk specifications in the
operating instructions of the manufacturer of the connected hydraulic system
before commissioning the control with a hydraulic system.
•• Please observe the general installation and safety instructions when working on
electric systems.
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
9/48
Safety instructions
•• The information given in the product documentation with regard to the use of
the supplied components are only application samples and recommendations.
The machine manufacturer and system installer must check the suitability of
the supplied components and the information given in this documentation with
regard to their use self-dependently for his individual application and adjust it to
the safety instructions and standards valid for his application, and carry out the
required measures, changes and amendments.
•• Technical data as well as connection and installation conditions are available in
the product documentation and must be imperatively observed.
•• In case of failures impairing the safety and modifications to the operating
behavior, shut down the VT-HNC100...3X immediately and report the failures to
the responsible personnel.
•• You must generally not modify or retrofit the product.
2.5 Product- and technology-related safety instructions
•• Dangerous motions
It is not allowed for persons to stay within the range of motion of machines
and machine parts. The following are examples of possible measures against
unintended access of persons:
–– Protective fences
–– Protective grids
–– Protective covers
–– Light barrier
•• If persons must access the danger zone during active control, monitoring
or measures must be provided for personal safety which are superior to the
system. These measures must be provided according to the specific data
of the system and on the basis of the risk and failure analysis of the system
manufacturer/user. In this connection, the safety requirements applied for the
system must be taken into account.
•• The VT-HNC100...3X itself does not include any safety functions for personal
safety and is no safety-relevant component. The VT-HNC100...3X is only
used to control the position, pressure, force and velocity of hydraulic axes for
machine functions.
•• In case of failures impairing the safety and modifications to the operating
behavior, shut down the VT-HNC100...3X immediately and report the failures to
the responsible personnel.
•• High electric voltage as a result of incorrect connection!
Danger to life, risk of injuries caused by electric shock!
–– Only use power packs with protective extra-low voltage (PELV) and/or if they
are safely separated from the mains circuits. For further information please
see IEC 60204-1.
–– All connections and clamps with voltages between 0 and 50 Volt may only be
connected with devices, electric components and lines with a protective extralow voltage (PELV).
–– Only connect voltages and electric circuits provided with a safe isolation from
dangerous voltages. Safe electrical isolation can be achieved for example
with isolating transformers, safe optocouplers or mains-free battery operation.
10/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Scope of delivery
2.6 Personal safety equipment
Check specified personal protection for completeness and protective effect and
have it available (please observer customer requirements and personal protection
list!)
3
Scope of delivery
The delivery contents include:
•• VT-HNC100...3X
•• Mating connector for X1S (Type Phoenix Mini Combicon 3-pole)
•• Mating connector for X2D (Type Phoenix Micro Combicon 6-pole or Phoenix
Mini Combicon 12-pole)
•• Mating connector X2A (Type Phoenix Micro Combicon 8-pole or HD-SUB 15pole)
•• Mating connector X8M (Type Phoenix Micro Combicon 8-pole or HD-SUB 15pole)
Accessories such as interface cables and cable sets are not included in the scope
of delivery and must be ordered separately. See chapter 6.2 “Recommended
accessories” on page 21.
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
11/48
Information on this product
4
Information on this product
4.1 Performance description
The digital axis control VT-HNC100...3X is a programmable NC control designed
for one to four controlled electro-hydraulic axes. The VT-HNC100...3X can be
connected to a superior control via a bus system (PROFIBUS DP, CANopen
or via the Ethernet-capable bus system PROFINET RT) and programmed
using a PC and the software program WIN-PED® version 6 and higher. The
Ethernet-capable variant requires WIN-PED® 7. TCP/IP is available optionally
to a PROFIBUS DP connection, see order option. Using the VT-HNC100...3X
it is possible to implement the control of position, pressure, force and velocity,
position-dependant braking, alternating control (position/pressure) and the
synchronization control of up to 4 axis, also in groups.
4.2 Product description
The VT-HNC100...3X is designed for being used in rough industrial environments
as regards to interference resistance, mechanical vibration and shock resistance,
and climate resistance.
The VT-HNC100...3X includes freely configurable controller variants:
••
••
••
••
Position / pressure / force and velocity controller
Position-dependent braking
Alternating control (position/pressure)
Synchronization control up to 4 axes, also in groups
For parameterization and diagnosis, the PC software WIN-PED® 6 or
WIN-PED® 7 is used which is available as free download for each control type
on the Internet under www.boschrexroth.com/hnc100. This allows for the
individual parameterization of the VT-HNC100...3X and its adjustment to the
requirements of your axes.
The chapter “First steps” describes the first steps when using the PC program
WIN-PED®. This chapter is also available as download on the same Internet site.
For process connection, the VT-HNC100...3X digital axis control is provided with
digital and analog transducer interfaces and up to eleven freely configurable
digital inputs/outputs. A bus system is available for the communication with the
superior control.
When using the unit, you moreover need superior control logics with
corresponding I/O components that in connection with the VT-HNC100...3X are
responsible for the holistic control of the machine's motion sequence and also its
monitoring as regards safety.
12/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Information on this product
Setup example
1$
1-$
).*
)JHIFSMFWFMDPOUSPM1-$PS1$
BOEWJTVBMJ[BUJPO).*
%JHJUBMJOQVUTPVUQVUTPSCVTTZTUFN
130'*#64%1$"/PQFO130'*/&535&UIFS/FU*1
(MPCBMCVT
$PNQBDUBYJT
$16BYJT
$16BYFT
$16BYFT
$16BYFT
75)/$$9
75)/$9
75)/$9
75)/$9
75)/$9
Fig. 1: System setup
The main operating ranges of VT-HNC100...3X include machine tools, plastic
machines, special-purpose machines, presses and transfer systems.
The technology functions include:
••
••
••
••
••
••
••
Process programming
Positioning
Pressure/force control
Differential pressure control
Synchronization
Curves
Cams
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
13/48
Information on this product
The preparation of user-specific data sets forms the basis for the function of the
VT-HNC100...3X. These data sets are created on the PC and submitted to the
VT-HNC100...3X via the serial interface or optionally the TCP/IP. The connection
between user program and data sets is referred to as project.
The VT-HNC100...3X includes different controller functions which are described in
the data sheet.
Technical data, operating conditions and the limitation of use of the
VT-HNC100...3X axis control are available in the data sheet.
4.3 Product identification
VT-HNC100
VT-HNC100 3X
= Serial unit
Option
000 =
without synchronization
G02 =
Synchronization 2-axis version
G03 =
Synchronization 3-axis version
G04 =
Synchronization 4-axis version
=C
=1
=2
=3
=4
Version Compact for 1 axis
Version for 1 hydraulic axis
Version for 2 hydraulic axes
Version for 3 hydraulic axes
Version for 4 hydraulic axes
Component series 30 to 39
(30 to 39: unchanged technical data and pinout)
00 =
No fitting
E0 =TCP/IP 1)
= 3X
Position transducer
I =Incremental/SSI
(not in connection with Compact version)
S =SSI
(only in connection with Compact version)
P =
Bus connection 2)
PROFIBUS DP
C =CANopen
N =
PROFINET RT
(not in connection with Compact version)
E =EtherNet/IP
(only in connection with Compact version)
1)Only
specify “E0” if the Ethernet service interface is desired
for “PROFIBUS DP”
2) Versions
Fig. 2: Order code
without bus connection are not available.
14/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Information on this product
4.4 Pin assignments
4.4.1 Pin assignment VT-HNC100-C-3X/...
(Compact)
The pins marked with “reserved” are reserved and must not be connected!
X8MEncoder
X3C Pin
8
7
6
5
4
3
2
1
Shield
24 Venc
+5 V
– Clk
+ Clk
– Data
+ Data
EGND
Pin
1
2
3
4
5
6
7
8
9
X2D
DIO (digital)

X2A
AIO (analog)
Pin
8
7
6
5
4
3
2
1
Shield
24 Vsens
Vout1 +
Vout2 +
Vin1
Cin2 +
Cin1 +
AGND

X1S Pin
1
2
3
TxD
RxD
reserved
GND
reserved
reserved
reserved
Power
GND
GND
18 – 30 V
X7P PROFIBUS DP
 
­€‚
Shield
OUT2
OUT1
IN4
IN3
IN2
IN1
DGND
Pin
8
7
6
5
4
3
2
1

RS232
ƒ
Pin
1
2
3
4
5
6
7
8
9
reserved
reserved
RxD/TxD-P
CNTR-P
DGND
VP
reserved
RxD/TxD-N
reserved
X7CCANopen
Pin
1
2
3
4
5
6
7
8
9
reserved
CAN_L
CAN_GND
reserved
reserved
reserved
CAN_H
reserved
reserved
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
15/48
Information on this product
4.4.2 Pin assignment VT-HNC100-1-3X/...
(1-axis version)
The pins marked with “reserved” are reserved and must not be connected!
X3C Pin
1
2
3
4
5
6
7
8
9
Slot 1 X8M1
Encoder
Incremental
TxD
RxD
reserved
GND
reserved
reserved
reserved
X1S Pin
1
2
3
RS232
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Power
GND
GND
18 – 30 V
SSI
– B (Inc)
+ CLK (SSI)
+ R (Inc)
– R (Inc)
+ A (Inc)
– A (Inc)
– CLK (SSI)
+ B (Inc)
– Data (SSI)
EGND
+ Data (SSI)
+5 Venc
+10 Vref
+24 Venc
reserved
X7E1, X7E2
Slot 1 X2D1
Pin

X7CCANopen
­
reserved
CAN_L
CAN_GND
reserved
reserved
reserved
CAN_H
reserved
reserved
Pin
1
2
3
4
5
6
7
8
9
€
‚
ƒ
‡
­
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
I/O 6
I/O 7
I/O 8
I/O 9
I/O 10
I/O 11
DGND
€
‚
ƒ
„
reserved
reserved
RxD/TxD-P
CNTR-P
DGND
VP
reserved
RxD/TxD-N
reserved
…„†„
Pin
1
2
3
4
5
6
7
8
9
X7P PROFIBUS DP

Ethernet
connection
1
2
3
4
5
6
7
8
9
10
11
12
DIO
(Digital)

Slot 1 X2A1 AIO
(Analog)
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Vin1 +
Vin1 –
Vin2 +
Vin2 –
Cin1 +
Cin1 –
Cin2 +
Cin2 –
reserved
AGND
Vout1 +
Vout2 +
Cout1
+24 Vsens
reserved
16/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Information on this product
4.4.3 Pin assignment VT-HNC100-2-3X/...
(2-axis version)
The pins marked with “reserved” are reserved and must not be connected!
X3C Pin
1
2
3
4
5
6
7
8
9
X1S Pin
1
2
3
RS232
TxD
RxD
reserved
GND
reserved
reserved
reserved
Slot 1 X8M1
Slot 2 X8M2
Encoder
Incremental
Pin
Power
GND
GND
18 – 30 V
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
SSI
– B (Inc)
+ CLK (SSI)
+ R (Inc)
– R (Inc)
+ A (Inc)
– A (Inc)
– CLK (SSI)
+ B (Inc)
– Data (SSI)
EGND
+ Data (SSI)
+5 Venc
+10 Vref
+24 Venc
reserved
X7E1, X7E2
Slot 1 X2D1
Slot 2 X2D2
DIO 1)
(Digital)
Pin
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
I/O 6
I/O 7
I/O 8
I/O 9
I/O 10
I/O 11
DGND
 ­
 ­
ƒ
ƒ
X7CCANopen
Slot 1 X2A1
Slot 2 X2A2
Pin

„

€

reserved
CAN_L
CAN_GND
reserved
reserved
reserved
CAN_H
reserved
reserved
€
Pin
1
2
3
4
5
6
7
8
9

„



…
reserved
reserved
RxD/TxD-P
CNTR-P
DGND
VP
reserved
RxD/TxD-N
reserved

†…‡…­
Pin
1
2
3
4
5
6
7
8
9

X7P PPROFIBUS DP
Ethernet
connection
‚
1) A
1
2
3
4
5
6
7
8
9
10
11
12
maximum of 20 digital outputs can be connected.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
AIO
(Analog)
Vin1 +
Vin1 –
Vin2 +
Vin2 –
Cin1 +
Cin1 –
Cin2 +
Cin2 –
reserved
AGND
Vout1 +
Vout2 +
Cout1
+24 Vsens
reserved
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
17/48
Information on this product
4.4.4 Pin assignment VT-HNC100-3-3X/...
(3-axis version)
The pins marked with “reserved” are reserved and must not be connected!
Pin
Encoder
Incremental
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Power
GND
GND
18 – 30 V
– B (Inc)
+ CLK (SSI)
+ R (Inc)
– R (Inc)
+ A (Inc)
– A (Inc)
– CLK (SSI)
+ B (Inc)
– Data (SSI)
EGND
+ Data (SSI)
+5 Venc
+10 Vref
+24 Venc
reserved
X7E1, X7E2
…
ƒ
ƒ
€
€
€



„

reserved
CAN_L
CAN_GND
reserved
reserved
reserved
CAN_H
reserved
reserved

X7CCANopen
Pin
1
2
3
4
5
6
7
8
9

„

‚
1) A
maximum of 20 digital outputs can be connected.
2) Not
available at slot 3 (reserved).
Slot 1 X2D1
Slot 2 X2D2
Slot 3 X2D3
DIO 1)
(Digital)
Pin
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
I/O 6
I/O 7
I/O 8
I/O 9
I/O 10
I/O 11
DGND
 ­

reserved
reserved
RxD/TxD-P
CNTR-P
DGND
VP
reserved
RxD/TxD-N
reserved
†…‡…­
Pin
1
2
3
4
5
6
7
8
9
 ­
 ­


Ethernet
connection
X7P PROFIBUS DP
SSI

TxD
RxD
reserved
GND
reserved
reserved
reserved
X1S Pin
1
2
3
Slot 1 X8M1
Slot 2 X8M2
Slot 3 X8M3

Pin
1
2
3
4
5
6
7
8
9

X3CRS232
1
2
3
4
5
6
7
8
9
10
11
12
Slot 1 X2A1
Slot 2 X2A2
Slot 3 X2A3
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
AIO
(Analog)
Vin1 +
Vin1 –
Vin2 +
Vin2 –
Cin1 +
Cin1 –
Cin2 +
Cin2 –
reserved
AGND
Vout1 +
Vout2 + 2)
Cout1
+24 Vsens
reserved
18/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Information on this product
4.4.5 Pin assignment VT-HNC100-4-3X/...
(4-axis version)
The pins marked with “reserved” are reserved and must not be connected!
X3CRS232
Pin
1
2
3
4
5
6
7
8
9
TxD
RxD
reserved
GND
reserved
reserved
reserved
X1SPower
Pin
1
2
3
GND
GND
18 – 30 V
Slot 1 X8M1
Slot 2 X8M2
Slot 3 X8M3
Slot 4 X8M4
Encoder
Incremental
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Slot 1 X2D1
Slot 2 X2D2
Slot 3 X2D3
Slot 4 X2D4
Pin
SSI
– B (Inc)
+ CLK (SSI)
+ R (Inc)
– R (Inc)
+ A (Inc)
– A (Inc)
– CLK (SSI)
+ B (Inc)
– Data (SSI)
EGND
+ Data (SSI)
+5 Venc
+10 Vref
+24 Venc
reserved
X7E1, X7E2
DIO 1)
(Digital)
1
2
3
4
5
6
7
8
9
10
11
12
Slot 1 X2A1
Slot 2 X2A2
Slot 3 X2A3
Slot 4 X2A4
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
I/O 6
I/O 7
I/O 8
I/O 9
I/O 10
I/O 11
DGND
Pin
 ­
 ­
AIO
(Analog)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Vin1 +
Vin1 –
Vin2 +
Vin2 –
Cin1 +
Cin1 –
Cin2 +
Cin2 –
reserved
AGND
Vout1 +
Vout2 + 2)
Cout1
+24 Vsens
reserved
 ­
 ­
„
ƒ
X7CCANopen




€
€



€

€

„

reserved
CAN_L
CAN_GND
reserved
reserved
reserved
CAN_H
reserved
reserved

Pin
1
2
3
4
5
6
7
8
9


ƒ



reserved
reserved
RxD/TxD-P
CNTR-P
DGND
VP
reserved
RxD/TxD-N
reserved

…
PROFIBUS DP
Pin
1
2
3
4
5
6
7
8
9
†…‡…­
X7P
Ethernet
connection
‚
1) A
maximum of 20 digital outputs can be connected.
2) Not
available at slot 3 and slot 4 (reserved).
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
19/48
Transport and storage
5
Transport and storage
There are no special transport instructions for this product. You must, however,
observe the notes in chapter 2 “General safety notes” and comply with the
ambient conditions for storage and transport which are detailed in the technical
data of data sheet 30139.
5.1 VT-HNC100...3X storage
Proceed as follows in order to prepare the VT-HNC100...3X for storage and
further use:
ff Only use the geniune packaging for storage.
ff Comply with the admissible storage temperature range of –20 °C to +70 °C.
ff Protect the VT-HNC100...3X from dust and humidity.
20/48
Bosch Rexroth AG
VT-HNC100...3X | RE 30139-B/10.11
Assembly
6
Assembly
NOTE
Risk of short circuit!
Water may condense within the housing!
ff Let the VT-HNC100...3X acclimate itself for several hours, as otherwise
water may condense in the housing.
The housing of the VT-HNC100...3X/ is perforated. According to the existing
protection class, dirt and fluids may easily enter and cause failures and a short
circuit! Safe functioning of the VT-HNC100...3X/ is thus no longer ensured.
ff When working on the VT-HNC100...3X you must make sure that everything
is clean and that no fluids will enter the housing.
Major potential differences!
Danger of destroying the VT-HNC100...3X by connecting or disconnecting plugs
under voltage.
ff Switch off power supply to the relevant system component before assembling
the unit or when connecting and disconnecting plug-in connectors.
6.1 Installation conditions
ff For installing the product always observe the ambient conditions specified in
the data sheet RE 30139.
NOTE: The environment must be free from electrically conductive contamination
(acids, bases, corrosive agents, salts, metal vapors, etc.) and the device must not
be exposed to these substances. Rule out any deposits according to protection
class IP 20.
The VT-HNC100...3X is intended for top hat rail assembly in the control cabinet.
The dimensions of each version are listed in the data sheet RE 30139.
ff Before commissioning, make sure that all the seals and plug of the plug-in
connection are installed correctly to ensure that they are leakproof and fluids
and contamination parts are prevented from penetrating the product.
RE 30139-B/10.11 | VT-HNC100...X
Bosch Rexroth AG
21/48
Assembly
6.2 Recommended accessories
The following accessories are recommended for the connection of the
VT-HNC100...3X axis control. These accessories are not included in the scope of
delivery, and can be ordered separately at Bosch Rexroth.
Table 6: Accessories
Component
Material number
RS232 interface cable, 1:1, length: 3 m
R900776897
USB RS232 converter
R901066684
Cable set VT17220-1X/HNC100...3X, length 2 m, for analog
signals (connection X2A) and digital position measurement
systems (connection X8M) with HD connector and open breakout
cable for:
VT-HNC100-1-3X, VT-HNC100-2-3X,
VT-HNC100-3-3X, VT-HNC100-4-3X
R901189300
Cable set VT17220-1X/HNC100...3X, length 2 m,for analog
signals (connection X2A) and digital position measurement
systems (connection X8M) with FK MC connector and open
breakout cable for: VT-HNC100-C-3X
R901189302
Plug-in connector Type 6ES7972-0BA42-0XA0 for PROFIBUS DP
R901312863
6.3 VT-HNC100...3X assembly
ff Lay the cables and lines so that they cannot be damaged and no one can trip
over them.
ff By snapping the housing of the VT-HNC100...3X/ on a conductive assembly
rail, the earth connection to the control cabinet rear wall is established. This
constitutes the HF earthing of the VT-HNC100...3X.
ff No silicone-containing sealing, adhesive, or insulating agents must be used.
ff Ensure a maintenance-friendly installation, i.e. simple access to the
connection lines. Free access to the connection side must be guaranteed.
ff Before installation note down the information on the nameplates. If, after the
installation, nameplates are no longer visible or legible, these data will be
quickly available to you at any time.
6.3.1 Place of installation
Do not install the HNC next to power electronics (e.g. frequency converters, etc.)
The power pack of the VT-HNC100...3X should be installed as close to the
VT-HNC100...3X as possible.
6.3.2 Voltage supply
ff The connection should be as short as possible. Pass supply and
return lines (+24 V/GND) together. Voltage 18-30 V with residual ripple
< 1.5 Vpp, I = 1 A - 4 A (depends on the HNC variant and the additional
supplied components).
•• Load lines of two individual wires (e.g. voltage supply) are to be passed in a
parallel or drilled form.
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Supply of external components
When supplying a 24 V encoder, the input voltage of the HNC100...3X at X1S
must comply with the encoder's requirements
(e.g. 24 V +/–5 %, residual ripple < 500 mV).
Analog components like pressure cells can be supplied via the sockets X2A1...4.
Prerequisite: The supply of the VT-HNC100...3X corresponds to the requirements
of the pressure cell. Further notes with regard to currents, etc. are available in the
data sheet RE 30139.
6.3.3 Screening
For signal lines, only cables with a copper braid shield should be used. The cable
shield is extensively connected with the metallized connector housing and only
on the VT-HNC100...3X side. This is achieved by pushing the screen back and
clamping under the pull relief.
6.3.4 General notes with regard to wiring
ff Observe the highest possible separation of signal and load lines and do not
lay the same parallel.
ff Do not pass the signal lines through strong magnetic fields.
ff Lay signal lines as continuously as possible. If intermediate terminals are
required, please use terminal block with shield strip and assembled
VT-HNC100...3X cable (max length 2m).
Exception: VT-HNC100-C-3X (Compact): Here, intermediate clamping using a
corresponding terminal block/shield strip is necessary for EMC-compliance.
Load lines of two individual wires (e.g. voltage supply) are to be passed in a
parallel or drilled form.
ff Cables should have the actually required number of wires only. If this is not
possible, you must connect the wires and connect them to the earth on one
side in the control cabinet.
6.3.5 Troubleshooting the system
In case of faults with the VT-HNC100 signals, you must check the troubleshooting
of other electric components, e.g. as follows:
Switched inductivities: DC: Antiparallel free-wheeling diode over actuator
winding
AC: Type-related R/C combination over actuator
winding.
Electric motors
R/C combination from each motor winding to earth.
Frequency converter
Input filter in the voltage supply of the frequency
converter.
Motor control line shielded and laid separately from
other lines, and/or output filter for motor lines.
Extensive contact of the FU housing with the rear
wall of the control cabinet
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Assembly
6.4 VT-HNC100...3X mechanical assembly
Assemble the VT-HNC100...3X on a top hat rail as follows:
ff Carefully engage the rear wall of the VT-HNC100...3X housing on a top hat
rail and check for safe seat. The mechanical contact points on the elastic rear
wall of the VT-HNC100...3X allow for a safe seat on the top hat rail and the
connection of the housing with the control cabinet's earthing system.
Connect
Press down
Engage
Fig. 3: VT-HNC100...3X assembly on the top hat rail
Contact points
Top hat rail 35 mm
TH 35-7.5 or TH 35-15
according to EN 60715
Fig. 4: Contact points of the VT-HNC100...3X for assembly on top hat rail
By snapping the housing of the VT-HNC100...3X/ on a conductive assembly
rail, the earth connection to the control cabinet rear wall is established. This
constitutes the HF earthing of the VT-HNC100...3X.
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6.4.1 HNC100...3X wiring
Use of pre-assembled breakout cables at the X8M encoder connector
interface and the analog I/O X2A
1
2
Fig. 5: Breakout cable with HD-SUB, 15-pole
1 Shield clamp:
The open end of the assembled breakout cable is connected with the terminal
block. Using a shield clamp which is adjusted to the shield strip, the pushed
back cable shield is pulled extensively to the potential of the control cabinet
rear wall, i.e the earth. The low-impedance connection of the conductibly
coated DIN rail to the control cabinet rear wall is important.
2 VT-HNC100...3X shield system
The cable shields are connected with the VT-HNC100 housing via the
HD-SUB connector. The connection with the control cabinet rear wall is
established via the housing and the DIN rail. Metalized D-sub connector
housings are used. The cable shield must be pushed back and clamped under
the pull relief. See illustration below.
Fig. 6: Breakout cable with 15-pole HD-SUB connector and open cable end
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Assembly
Max. length of the cable: 2 m
Note: On the side of the breakout cable, all wires must be connected to the
terminal strip. Otherwise there is a risk of short circuit!
The earthing of the control cabinet must be considered accordingly.
Wiring diagram for analog (X2A) or digital interface (X8M)
VT17220-1X/HNC100...3X & material number: R901189300
1
2
3
4
6
5
Provide litz wire
with pos. 6 wire
end ferrules
Printed on the cable on both ends (smear-resistant), text height 3 mm
Shrink shield onto cable sheath
using a shrinkable tubing
Shield put over outer
sheath
Fig. 7: Wiring diagram for analog or digital interface
1 HD sub connector high density 15-pole with solder bucket
2 D-SUB housing, 9-pole, metal/UNC (Mat. no. R900016918)
3 Shrinkable tubing 30 mm
4 Cable Unitronic LiYCY 8 x 2 x 0.14 mm2, approx. 2.2 m
5 Shrinkable tubing 40 mm
6 Wire end ferrules
NOTE: Type and manufacturer of item 2 are binding (housing dimensions)!
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Assembly
Table 7: Pin assignment
1
Black
2
3
Pink
Grey/Pink
4
Red/Blue
5
White/Green
6
Brown/Green
7
8
Grey
9
10
11
Violet
Yellow
White + Blue
Green
12
Brown
13
White/Yellow
14
Red
Yellow/Brown
15
Slot X2A1
AIO (analog)
Slot 1 X8M1
Encoder
Pin 1
Vin 1 +
Pin 1
Pin 2
Vin 1 –
Pin 2
Pin 3
Vin 2 –
Pin 3
+R
Pin 4
Vin 2 –
Pin 4
–R
Incremental
SSI
–B
+ CLK
Pin 5
Cin 1 +
Pin 5
+A
Pin 6
Cin 1 –
Pin 6
–A
Pin 7
Cin 2 +
Pin 7
Pin 8
Cin 2 –
Pin 8
Pin 9
reserved
Pin 9
Pin 10
AGND
Pin 10
– CLK
+B
– Data
EGND
Pin 11
Vout 1
Pin 11
Pin 12
Vout 2
Pin 12
+ Data
Pin 13
Cout 1
Pin 13
+10 Vref
Pin 14
24 Vsens
Pin 14
+24 Venc
Pin 15
reserved
Pin 15
reserved
+5 Venc
VT-HNC100 Compact
HNC100...3X shield system:
2
1
Fig. 8: Breakout cable with micro Combicon connector, 8-pole
1 Shield clamp:
The open end of the assembled breakout cable is connected with the terminal
block.
Using a shield clamp which is adjusted to the shield strip, the pushed back
cable shield is pushed extensively to the potential of the control cabinet rear
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Assembly
wall, i.e the earth. The low-resistance connection of the conductibly coated
DIN rail taddo the control cabinet rear wall is important.
2 VT-HNC100...3X Compact shield system
The cable shields are connected with the VT-HNC100 housing via the shield
pin of the Micro Combicon connector. The connection to the control cabinet
rear wall is established via the housing and the DIN rail.
An intermediate terminal block with shield strip must be used. See illustration
below.
Fig. 9: Micro-Combicon connector and open cable end
Wiring diagram for analog (X2A) or digital interface (X8M)
VT17220-1X/HNC100...3X & material number: R901189302
Black litz wire soldered to the shield
1
2
3
4
5
Provide litz wires
with pos. 5 wire end
ferrules
Shrink black litz wire
after soldering
Printed on the cable on both ends (smear-resistant, text height 3 mm)
Shrink shield onto cable sheath
using a shrinkable tubing
Shield put over outer
sheath
Fig. 10: Wiring diagram for analog or digital interface
1 8-pole Micro Combicon connector FK-MC 0.5/-ST-2.5
2 Shrinkable tubing 30 mm
3 Unitronic LiYCY cable 4 x 2 x 0.25 mm2, approx. 2.2 m long
4 Shrinkable tubing 40 mm
5 Wire end ferrules
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Assembly
Table 8: Pin assignment
8
Black
7
Red
6
Brown
5
Grey
4
Pink
3
Yellow
2
Green
Blue + White
1
Slot X8M
Encoder
Slot X2A
AIO
(Analog)
Pin 8
Shield
Pin 8
Shield
Pin 7
24 Venc
Pin 7
24 Vsens
Pin 6
+5 V
Pin 6
Vout 1
Pin 5
– Clk
Pin 5
Vout 2
Pin 4
+ Clk
Pin 4
Vin 1
Pin 3
– Data
Pin 3
CIN2 +
Pin 2
+ Data
Pin 2
CIN1 +
Pin 1
EGND
Pin 1
AGND
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Assembly
6.4.2 Wiring instructions for pressure transducers
The figure shows a wiring example. Screening is not taken into account. See
chapter 6.4.1 “VT-HNC100...3X wiring”.
Fig. 11: Wiring for pressure transducers
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Fig. 12: Wiring for pressure transducers
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Assembly
Fig. 13: Forwarding a pressure transducer signal (not for Compact version)
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Assembly
6.4.3 Description of the LEDs
At the front side of the VT-HNC100...3X unit, there are the following 3 LED
displays:
•• 3.3 V: Voltage supply of the VT-HNC100...3X is OK.
•• RUN: VT-HNC100...3X has been initialized and is in “RUN”. The LED flashes
if the VT-HNC100...3X has not been initialized.
•• BUS: Field bus communication is OK.
If the following variants are used: HNC with PROFINET RT, EtherNet/IP or
PROFIBUS and optionally with TCP/IP, the following additional LEDs are used:
•• NS: Network status
LED off = no IP address
LED green (flashing) = configuration
LED green = connection established
LED red (flashing) = connection interrupted
LED red = double IP address
•• MS: HACD status:
LED green (flashing) = configuration
LED green = HACD OK
LED red (flashing) = error
•• L:
Link: On = Active; Off = No connection to the communication partner
•• S: Transmission status of the data (flashing = Receiving/sending EtherNet
telegrams).
6.4.4 CANopen
The CANopen interface as well as the operation of the VT-HNC100...3X via
CANopen is described in detail in the online help
Fig. 14: CANopen interface
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Assembly
Fig. 15: VT-HNC100 address with CANopen
Fig. 16: Baud rate for CANopen
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6.4.5 PROFIBUS DP
The PROFIBUS DP interface as well as the operation of the VT-HNC100...3X via
CANopen is described in detail in the online help.
Fig. 17: RROFIBUS DP interface
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Assembly
Fig. 18: Address setting for PROFIBUS DP
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Fig. 19: PROFIBUS DP baud rate
6.4.6 Setting the address switch
The address switch is located at the front side of the housing of the
VT-HNC100...3X
A binary setting of 1 to 127 addresses is possible.
In switch position 0 = boot mode, all data can be transferred.
6.4.7 PROFINET RT / EtherNet IP
Here, the IP address is assigned with WIN-PED® 7. The address switch at the
front side is without any meaning.
Further information is available in the online help of WIN-PED® 7.
6.4.8 PROFIBUS DP with TCP/IP
Here, the IP address is assigned with WIN-PED® 7. The address switch at the
front side is without any meaning.
Further information is available in the online help of WIN-PED® 7.
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Commissioning
7
Commissioning
7.1 First commissioning
NOTE
Uncontrolled connection or disconnection of plug-in connectors!
The device might be destroyed.
ff Before installation works, and before connecting or disconnecting plug-in
connectors to or from the device, the device must be disconnected from the
voltage supply or reliably de-energized.
Devices damaged due to incorrect installation are not covered by the
warranty.
ff Observe protection class, voltage supply and environmental conditions
according to data sheet RE 30139.
The basis for the functionality of the VT-HNC100...3X is the preparation of the
application with software WIN-PED® 6 or WIN-PED® 7. For operation, the
VT-HNC100...3X must be connected with the PC ready for operation, and the PC
must be online.
It is also possible, to start the acceptance of existing project data from the
VT-HNC100...3X directly from the program WIN-PED® 6.X. In this case too,
the VT-HNC100...3X must be connected with the PC ready for operation, and
the PC must be online.
ff Select the “Communication” menu.
ff Select “Upload data” and “Search directly connected controls”.
After the acceptance of the existing project data and the HNC software, the
program WIN-PED® 6.X is ready for operation together with the
VT-HNC100...3X, and the actual project planning, programming and diagnosis
of the control system can be started.
The HNC software version with which the VT-HNC100...3X was initialized,
must already be installed on the PC before project data can be acquired.
Further information on operation, project planning, programming and diagnosis
of the control system with WIN-PED® 6 is available in the help menus of the
program.
7.2 Commissioning software WIN-PED® 6 and
WIN-PED® 7
For commissioning and for later operation, the user can apply the PC program
WIN-PED®. It can be used for the programming, setting and diagnosis of the
VT-HNC100...3X. Functionality, menus and program windows are adjusted to the
variants of VT-HNC100...3X.
Projects established with WIN-PED® 6 are not compatible with projects from
WIN-PED® 7. Automatic conversion is not possible. However, it is possible to edit
the projects manually.
Ethernet-capable hardware requires WIN-PED® 7. Any other hardware version
operates both with WIN-PED® 6 and WIN-PED® 7.
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Commissioning
WIN-PED® offers the following functions:
••
••
••
••
••
Convenient dialog functions for the online or offline settings of the machine data
NC editor with integrated syntax check and program compiler
Support for the definition of the parameters used in the NC program
Dialog window for the online setting of the parameter values
Various options for the display of the process parameters for digital inputs,
outputs and flags
•• Recording and graphic illustrations of up to 16 process parameters with a great
choice of trigger options
•• Dialog for the graphic definition of special functions (determination of the
function through a traverse)
•• Bus manager for the configuration of data exchange (PROFIBUS DP,
PROFINET RT or CANopen) with superior control
The PC program “WIN-PED” is not included in the scope of delivery of the
VT-HNC100...3X. Download on the Internet:
www.boschrexroth.com/hnc100
7.3 Installation requirements
The following system specifications are required for the PC program WIN-PED®:
••
••
••
••
••
••
IBM PC or compatible system
Windows XP or Windows 7 for WIN-PED® 6
Windows XP or Windows 7 for WIN-PED® 7
Main memory (recommendation: 512 MB)
100 MB available hard drive capacity for each control type
RS 232 interface for VT-HNC100...3X connection; for the PROFINET RT,
EtherNet/IP or PROFIBUS DP, also the network interface TCP/IP can be used
•• An interface cable RS232 (length 3 m; Material no. R900776897) as well
as an USB RS232 converter (Material no. R901066684) are not included in
the scope of delivery, can, however, be ordered separately. See chapter 6.2
“Recommended accessories” on page 21.
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Commissioning
7.3.1 HNC - PC connection via serial interface
Establish the connection between the VT-HNC100...3X and your PC as follows:
Fig. 20: Connection and required accessories
7.3.2 HNC - PC connection via TCP/IP
For Ethernet-capable VT-HNCs, TCP/IP is optionally available as alternative for
the serial interface. Please observe the notes in the order code.
Make the VT-HNC100...3X ready for operation:
ff Carefully check the wiring.
ff Apply operating voltage to the VT-HNC100...3X.
Please observe the instructions for the installation program when installing
WIN-PED®.
ff After having installed the program, you can start it by clicking on it.
Furthermore, the control type applicable for the HNC software must be installed.
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Commissioning
The control types are listed on the download site for WIN-PED®.
The HNC software must be installed after download:
ff Follow the installation instructions.
After having installed WIN-PED® and the control types, the WIN-PED®
program is ready for operation, and you can start the actual project planning,
programming and diagnosis of the control system.
The “First steps” which are available as download under
www.boschrexroth.com/hnc100 will support you when learning how to
use the software WIN-PED®.
Fig. 21: Download page for WIN-PED® and “First steps”
Fig. 22: First steps overview in WIN-PED® 6
The “First steps” will guide you through the whole installation and describe step
by step the creation of a new project, communication settings, the activation of
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Operation
the communication between PC and VT-HNC, the initializing of the control, the
archiving of data in the control and the acquisition of data from the control.
ff Creating a new project using the installed HNC software.
ff After having completed project planning and programming, the VTHNC100...3X must be initialized with this project. Then, the VT-HNC100...3X
is ready for operation.
8
Operation
During normal operation, the user does not need to intervene.
In case of mains failure during operation, the VT-HNC100...3X can be switched
on again without any further measures and is ready for operation.
8.1 Software description
The WIN-PED® software is described in the previous chapter 7 “Commissioning”.
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Maintenance and repair
9
Maintenance and repair
9.1 Cleaning and care
NOTE
Failures!
Loss of functionality due to penetrating dirt and humidity!
ff Always provide for absolute cleanness when working on the VT-HNC100...3X.
ff Only use a dry and dust-free cloth for all cleaning works.
Aggressive detergents may damage the VT-HNC100...3X and let it age faster.
Never use solvents or aggressive detergents.
For cleaning and maintenance proceed as follows:
ff Perform a visual inspection for checking the tight seat of all lines and screws.
ff Check all plug-in and clamping connections of the VT-HNC100...3X for correct
seat and damage at least once per year.
ff Check lines for breakage and squeezing. Have damaged or defective lines
exchanged immediately!
ff Clean housing parts with a dry and dust-free cloth.
9.2 Maintenance
The maintenance of the VT-HNC100...3X is limited to the cleaning of the surface
in order to avoid that dirt and humidity will enter the housing. Regularly check the
VT-HNC100...3X for dirt and correct connections taking into account the ambient
conditions.
9.3 Repair
The VT-HNC100...3X can only be exchanged as whole unit. For safety reasons,
modifications at the VT-HNC100...3X performed to one's own authority are not
admissible! Repair and maintenance works may only be performed by Bosch
Rexroth AG. For repair and maintenance works, send the unit to the service
address specified in chapter 15.
Devices returned to Bosch Rexroth for repair must be sent in original packaging.
Repaired devices are returned with default settings.
User-specific settings are not accepted. The user must transfer all appropriate
user parameters and programs again.
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Disassembly and replacement
10 Disassembly and replacement
10.1 Preparing for disassembly
NOTE
The device might be destroyed!
ff Decommission the entire system as described in the overall system manual.
ff De-energize the device and all connected components.
10.2 Disassembling the digital axis control
Proceed as follows to disassemble the VT-HNC100...3X:
ff Pull off the connection lines and plugs.
ff Release the VT-HNC100...3X from the top hat rail.
Apply pressure and
tilt out top down.
Press down
Fig. 23: VT-HNC100...3X disassembly from the top hat rail
10.3 Preparing the components for storage/further use
Proceed as follows in order to prepare the VT-HNC100...3X for storage and
further use:
ff Only use the geniune packaging for storage.
ff Observe the admissible storage temperature range that is specified in
RE 30139.
ff Protect against dust and humidity.
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Disposal
11 Disposal
11.1 Environmental protection
Careless disposal of the VT-HNC100...3X and the packaging material could lead
to pollution of the environment.
ff Thus, dispose of the VT-HNC100...3X and the packaging material in
accordance with the currently applicable national regulations in your country.
11.2 Return to Bosch Rexroth
The products manufactured by us can be returned to us for disposal purposes
at no costs. However, the precondition is that there are no spurious adherences
or any other contamination. Furthermore, there must be no inappropriate foreign
matter or third party components when products are returned.
The products have to be sent free to the door to the following address:
Bosch Rexroth AG
Service Industriehydraulik [Industrial hydraulics]
Bürgermeister-Dr.-Nebel-Straße 8
97816 Lohr am Main
Germany
11.3 Packagings
Upon request, reusable systems can be used for regular deliveries. The materials
for one-way packagings are mostly cardboard, wood, and styrofoam. These
can be disposed of without any problems. Due to ecological reasons, one-way
packagings should not be used for returning products to us.
11.4 Materials used
Our products do not contain any hazardous materials that could be released
during intended use. Normally, no adverse effects on human beings and on the
environment have to be expected.
The products essentially consist of:
• Electronic components and assemblies
11.5 Recycling
Due to the high share of metals the products can mostly be recycled. In order
to achieve an ideal metal recovery, disassembly into individual assemblies is
required. The metals contained in electric and electronic assemblies can be
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Extension and conversion
recovered by means of special separation procedures as well. If the products
contain batteries or accumulators, these have to be removed before recycling and
furnished to the battery recycling, if possible.
12 Extension and conversion
The VT-HNC100...3X may neither be extended nor converted. If you convert the
VT-HNC100...3X, warranty will expire.
13 Troubleshooting
13.1 How to proceed with troubleshooting
•• Always work systematically and focused, even when under time pressure.
Random and imprudent disassembly and readjustment of settings might, in the
worst-case scenario, result in the inability to restore the original error cause. By
readjusting parameters, the drive units operate in an uncontrolled or vibrating
manner or do not operate at all due to changed command values, or that they
react in any other unexpected way.
•• First get a general idea of how your product works in conjunction with the entire
system.
•• Try to find out whether the product has worked properly in conjunction with the
entire system before the error occurred first.
•• Try to determine any changes of the entire system in which the product is
integrated:
–– Were there changes to the product's operating conditions or operating range?
–– Were there any changes or repair works on the entire system (machine/
system, electrics, control) or on the product?
If yes: What were they?
–– Was the product or machine used as intended?
–– How did the malfunction become apparent?
–– Try to get a clear idea of the cause of the fault. Directly ask the (machine)
operator.
•• For troubleshooting, you can use the diagnosis options of WIN-PED® 6 or 7.
The diagnosis and failure messages can optionally be read out via field bus.
If you could not remedy the occurred fault, please contact one of the addresses
you find at http://www.boschrexroth.com or in the address directory in the
annex. In case of WIN-PED® software failures, you can visit the website www.
boschrexroth.com/hnc. Here, software updates or occurred faults and their
remedy are explained.
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Technical data
14 Technical data
Technical data vary according to the version of the VT-HNC100...3X. A detailed
description of you axis control is available in the data sheet RE 30139.
In addition, you can here find data on the two bus systems PROFINET RT
and EtherNet/IP:
Bus system
Functionality
PROFINET RT
EtherNet/IP
PROFINET IO RT Device
EtherNet/IP adapter
Conformance Class A
Remote Reset: 0/1
Protocols (CM, RTC, RTA, ARP, ICMP,
LLDP)
Connection Classes 1/3(Exclusive Owner,
Listen Only)
Alarm support
Unconnected Explixit Messaging
Max. 1 API supported
DHCP support
Minimum cycle time
Max. size of the cyclic I/O data
2 ms
992 byte (max. 496 496 byte per direction)
Transmission rate
Interface
100 Mbit/s, full-duplex
Integrated cut-through switch
– 3-port switch (2 x external, 1 x internal)
– Pass-through delay min. 0.9 us / max. 1.4 us
Specification
Diagnosis LED
Conformity with the relevant IE standard
2 x port status LEDs (Link, Activity)
1 x module status (red / green)
1 x network status (red / green)
Recommendations for bus operation
–Separation of the IE network from standard Ethernet network (company network)
–Alternative connection to the superior standard Ethernet company network via router
(e.g. level-3 router)
–Separation of standard Ethernet devices (e.g. PCs) in other partial areas (segments) with
additional integration into the IE network
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Appendix
15 Appendix
15.1 Address directory
15.1.1Contact person for repair
Bosch Rexroth AG
Service Industriehydraulik [Industrial hydraulics]
Bgm.-Dr. Nebel-Str. 8
97816 Lohr am Main
Germany
http://www.boschrexroth.com/service
eMail: [email protected]
15.1.2Contact person for support
Bosch Rexroth AG
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 (93 52) 18-11 32
Fax
+49 (93 52) 18-33 63
eMail: [email protected]
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 9352 18-0
Fax
+49 9352 18-23 58
[email protected]
www.boschrexroth.com
Subject to change without notice
Printed in Germany
RE 30139-B/10.11
VT-HACD-1 – Digital controller
for electromechanical
and electrohydraulic drives
Installation and Operation
RE 30143-B/08.07
Replaces: 04.07
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Bosch Rexroth AG | Hydraulics
Installation and Operation | RE 30143-B/08.07
RE 30143-B/08.07 | Installation and Operation
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Contents
1
General ....................................................................................................... 5
1.1
Document .................................................................................................... 5
1.2
About this Manual ........................................................................................ 5
Additional Documentation ............................................................................................ 5
Characters and Symbols .............................................................................................. 6
1.3
Scope of Supply........................................................................................... 6
1.4
Requirements .............................................................................................. 7
2
Installing the HACD ................................................................................... 8
2.1
Safety Requirements ................................................................................... 8
Proper Use ................................................................................................................... 8
Personnel Selection and Qualification.......................................................................... 9
Design Changes and Electrical Installation .................................................................. 9
2.2
Repair and Troubleshooting ...................................................................... 10
2.3
Transport, Storage and Handling the Controller Card ............................... 11
2.4
Card Installation......................................................................................... 12
2.5
Edge Connector Terminals and Pin Assignments ..................................... 13
2.6
Installation Local Bus................................................................................. 17
3
Startup of the HACD Controller Card..................................................... 18
3.1
Preparing for Use....................................................................................... 18
3.2
Installing BODAC software ........................................................................ 19
Installation Requirements ........................................................................................... 19
BODAC Setup ............................................................................................................ 19
3.3
Initial startup with BODAC ......................................................................... 20
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Installation and Operation | RE 30143-B/08.07
4
HACD Operation ...................................................................................... 21
4.1
Display/Input Keys and Connectors on the Front Panel ............................ 21
4.2
Diagnostics Test Jacks .............................................................................. 23
4.3
Menu Tree for Setup and Parameters ....................................................... 24
4.4
Display/Input Key Operations .................................................................... 35
5
Diagnostics .............................................................................................. 40
5.1
Diagnostic Options on the HACD Controller Card ..................................... 40
5.2
Diagnostics Using BODAC ........................................................................ 41
6
Detecting Errors....................................................................................... 42
6.1
Error Messages ......................................................................................... 42
6.2
Changing fuses.......................................................................................... 43
7
Index ......................................................................................................... 45
RE 30143-B/08.07 | Installation and Operation
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General 1
1
General
1.1
Document
Version 1.2
1.2
About this Manual
Before installing or operating your HACD Controller card for the first time, you should
read this Manual. Please note the safety requirements described in section 2.1
Persons involved with the start-up and operation of the controller card should have
proper training on the installation and operation of this type of equipment.
This manual is intended to inform you about the functions of this controller card and its
intended use.
The Manual contains important safety instructions on proper installation and operation
of the controller card. Observing these instructions will help you:
„
avoid hazards and dangers
„
minimize repair costs and downtime
„
increase the useful life and reliability of the controller card.
Additionally, please observe all regulations that are in effect in the country and/or
community to prevent accidents and to protect the environment.
This manual only describes the installation and operation of the controller card. Information about starting up the controller card using BODAC software is located in a
separate document: “Operation of the BODAC Software and Starting up the HACD
Control Card”. A list of documentation for the HACD can be found in the “Additional
Documentation" section.
Additional Documentation
Included with this manual is the document “HACD Digital Controller for Electromechanical and Electrohydraulic Drives".
It contains:
„
RE sheet "RE 30 143" in paper form.
„
Document RE 30 143-B: "Starting up the HACD Control Card and Operation of
the BODAC Software" (included with the shipment).
„
Internet: http://www.boschrexroth.com/hacd
(Navigation: Industrial Hydraulics
-> Products and Solutions -> Product Overview -> digital amplifiers / Controller)
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Installation and Operation | RE 30143-B/08.07
1 General
Characters and Symbols
The following characters and symbols are used in the manual:
„
Action symbol: The text following this symbol describes actions. These should be
performed, from top to bottom, in the given order.
„
Result symbol: The text following this symbol describes the results of an action.
Following this symbol you will find notes and useful tips for optimal use of
the controller card.
Warning symbols
Special safety notes are provided at the relevant locations. These are indicated by the
following symbols.
General hazard potential
Indicates a potentially hazardous condition which, if not avoided, could
result in death or serious injury.
If the hazard source can be specifically indicated, the corresponding pictogram will be
used.
Electrical current hazard
This symbol refers to a hazardous condition caused by electrical current which, if not avoided, could result in death or serious injury.
Equipment damage
This symbol pertains to actions which could result in damage to equipment.
1.3
Scope of Supply
The equipment is packed in anti-static packaging to protect the controller card from
electrostatic discharge. Observe instructions on the top side of the packaging.
Included in the shipment:
„
HACD Controller Card
„
RE sheet RE 30 143
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General 1
1.4
Requirements
Mounting the controller card in a 19” rack:
„
VT 19 101
„
VT 19 102
„
VT 19 103
„
VT 19 110.
described in datasheet RE 29 768, or mounted in a card holder
„
VT 3002-2x/G64
described in datasheet RE 29 928.
The card holder should be used only inside a control cabinet, as there is no protection
from accidental contact.
If no power is provided by the user, the following power supply is available as an option:
„
VT-NE30
described in datasheet RE 29 929.
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2 Installing the HACD
2
Installing the HACD
2.1
Safety Requirements
Operate the HACD controller card only if it is not damaged and is in proper operating
condition and is applied for its intended purpose. Observe all safety and hazard instructions in the included documentation.
When faults occur, which compromise safety and result in changes in operating conditions, shut down the controller card immediately and notify responsible personnel.
Fault free and safe running of the controller card assumes appropriate transport, storage and installation, as well as proper startup and operation.
The HACD Control Card has been built using the latest technology, and in accordance
with recognized safety standards. Nevertheless, operation may result in hazard to
persons or property if:
„
The HACD Controller Card is not used properly.
(see page 9, Proper Use)
„
The HACD Control Card is not installed, commissioned and operated by qualified
persons.
„
Changes or modifications are made to the HACD controller card.
„
Safety requirements and safety notes are not observed.
The HACD controller card is intended for industrial use.
The card must not be operated until it has been determined that the system in which
the controller card is installed, meets all applicable standards and safety regulations
for the application.
In European countries: EC Directive 89/392/EWG (Machine Directive)
Operation is permitted only when applicable EMC regulations for the application are
met.
Adherence to limits defined by regulations and standards are the responsibility of the
manufacturer of the system or machine.
In European countries: EC Directive 89/336/EWG (EMC Directive)
In the United States: National Electrical Code (NEC) and National Electrical Manufacturers Association (NEMA), as well as local standards should be observed. The operator is required to adhere to the above named standards at all times.
Proper Use
The HACD controller card is designed for controlling electromechanical and electrohydraulic drives.
Applications include:
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Installing the HACD 2
„
open loop control
„
closed loop position control
„
closed loop speed control
„
closed loop pressure and force control
„
valve controller
Proper use requires adherence to the manuals and supplementary documentation,
and observing relevant safety and operating standards.
Personnel Selection and Qualification
Operating and Startup
Operation and startup of the HACD controller card requires specialized skills. Therefore this work should be performed only by properly trained individuals.
Only persons who are trained or properly instructed should start up and operate the
HACD controller card. Additionally the oversight of a qualified supervisor may be
advised.
Personnel are considered qualified if they are familiar with the installation, startup and
operation of the HACD controller card, and with all the warning notes and safety regulations contained in the accompanying documentation.
Work on the electrical equipment must be performed only by qualified specialists or by personnel appropriately instructed and under the supervision and
guidance of persons qualified and familiar with electrical safety standards.
An electrical specialist is someone who, based on his technical knowledge and training, as well as knowledge of the relevant standards, is able to evaluate the tasks assigned to him, recognize potential hazards and take the appropriate safety measures.
Repair and troubleshooting
Repair and troubleshooting requires specialized skills. Therefore, this work should be
performed only by trained and designated specialists.
Design Changes and Electrical Installation
User changes to the HACD controller card may result in safety hazards.
Note the following recommendations on electrical installation:
„
Use low-capacitance cables. Make cable connections without intermediate connections whenever possible.
„
Control electronics should be isolated from electromagnetic noise sources (IE:
V/F drives).
„
Power wiring should not be routed in the vicinity of control electronics.
„
Power wiring should not be routed in the vicinity of control wiring or cables.
„
Route sensor lines separately.
„
Maintain a distance of at least 1 meter from antenna lines, RF devices and radio
equipment.
„
When using differential inputs switch both inputs on and off at the same time.
„
When switching signal inputs, use dry circuit rated relays with gold-plated contacts (low voltages, low currents)
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2 Installing the HACD
2.2
„
Always shield all analog signal lines. Connect shields at the card end only, connecting to the "Shield" terminal, and leave the other end open to prevent ground
loops.
„
Connect to an appropriate system ground using stranded copper wire (min
2.5mm2 / 12 AWG)
The system ground is an essential component of the EMC protection for the controller card. The ground provides a path for noise that could otherwise enter the
controller card through the signal and power supply lines. Noise is bypassed only
if the system ground does not couple noise into the controller card.
Rexroth also recommends shielding solenoid wiring.
„
Do not use logical signals from the controller card (IE: “OK” signal) for switching
machine safety circuits
(see European Norm "Safety Requirements for Fluid Power Systems and Components" EN982:1996).
Repair and Troubleshooting
If the control cabinet contains additional electrical components utilizing high voltage,
always observe safety standards to prevent accidents ! Use appropriate protective
gear, such as safety shoes and safety gloves, when prudent !
Use appropriate tools (IE: insulated tools)
Before opening control cabinet doors, open the main disconnect.
To ensure safe working conditions, observe the following safety rules:
„
Remove all power
„
Ensure against unintended energization: lockout devices when possible, and use
lockout warning tags
„
Verify that voltage is not present
„
Cover or close off adjacent areas that are still energized.
If work on energized components is necessary, have a second person present as a
safety backup to actuate an E-STOP switch or open the main disconnect, if necessary. Use insulated tools only
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Installing the HACD 2
2.3
Transport, Storage and Handling the Controller Card
The packaging contains notes on handling of the controller card. These must be
strictly followed.
SDLC
ACHTUNG
Elektrostatisch gefährdete
Bauelemente.
ATTENTION
Static Sensitive
Devices
ATTENTION
Circuits sensibles à
l' électricité statique.
Handle only at
Static Safe Work
Stations
Manipulation uniquement Handhabung daher nur an
autorisée sur un poste de geschützten Arbeitsplätzen
erlaubt.
travail protégé.
HACD_HW_DE_2-1
Fig. 1 Notes for handling printed on the packaging
Observe the following:
„
Keep the controller card away from moisture and dust
„
Observe the allowable storage temperature range of –20° C to +70 °C.
(allowable operating temperature: 0 – 50° C)
NOTE!
Electrostatic discharge (ESD) can damage components on
the controller card. To prevent damage, observe the following
recommendations
Discharge static voltage from your body using accepted practices.
Work in a safe environment. Do not use any devices in the working environment that generate or hold static charge. Avoid working
with the controller card in areas where floors or work surfaces is
composed of materials that can generate a static charge.
Handle the controller card carefully. Do not touch any exposed
pins or electronic components.
Transport and store the control card in its original packaging.
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2 Installing the HACD
2.4
Card Installation
Remove the card from its packaging only at a protected work place.
Do not touch any electrical components when placing the controller card in its proper
card holder as shown in Fig. 2..
Correctly installing the HACD controller card:
¾
Remove power from the rack when installing the card.
¾
Hold the card by the front panel and remove it from the packaging.
¾
Slide the card into the guide rails of the rack without using excessive force, as
shown in Fig. 2 “Installing the control card”.
¾
Snap the edge connector in place by gently pressing on the front panel.
card
male connector
mounting
screws
guide rails
Faceplate
HACD_HW_EN_2-2
Fig. 2 Installing the controller card
¾
Tighten the two mounting screws on the front panel.
9
The card is now installed correctly.
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Installing the HACD 2
2.5
Edge Connector Terminals and Pin Assignments
The edge connector is a 64-pin, Type G (DIN 41612).
The pin assignments for the edge connector are not fully downward compatible with
older amplifier products.
Differences in pin assignments have been implemented such that damage is prevented if an old controller card is replaced by an HACD controller card.
Pin assignment tables:
Row d
Pin
Description
Type
Specification
2
DI 1
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
4
DI 2
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
6
DI 3
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
8
DI 4
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
10
DI 5
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
12
DI 6
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
14
DI 7
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
16
DI 8
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub
18
DI 9
Discrete input
log 0 = 0..5V,
log 1 = 16..Ub (H active)
20
DO 1
Discrete output
Ub-3V, 30mA, short-circuit
protected
22
OK
Discrete output
Ub-3V, 30mA, short-circuit
protected
24
Data +
Local CAN Bus
Input/Output
CAN Specification
26
DO 2
Discrete output
Ub-3V, 30mA, short-circuit
protected
28
Data –
Local CAN Bus
Input/Output
CAN Specification
30
AO 1
Analog output
± 10V, Rlast min = 1k
0-10V; Rlast min = 1k
0-20mA, Rlast max = 500R
4-20mA; Rlast max = 500R
32
AO 2
Analog output
± 10V, 10mA Rlast min = 1k
Tab. 1 Pin assignment of edge connector Row d
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2 Installing the HACD
Row b:
Pin
Description
Type
Specification
2
AI3+
Differential input
Differential input:
± 10V (Rin>100kΩ),
4
AI3-
Differential input
0...20mA with Rin = 100Ω
6
AI2+
Differential input
Differential input:
± 10V (Rin>100kΩ),
8
AI2-
Differential input
0...20mA with Rin = 100Ω
10
AI1+
Differential input
Differential input:
± 10V (Rin = >10MΩ),
12
AI1-
Differential input
0...20mA with Rin = 100Ω
14
AI4+
Differential input
Differential input:
± 10V (Rin>100kΩ),
16
AI4-
Differential input
0...20mA with Rin = 100Ω
18
AI5+
Differential input
Differential input:
± 10V (Rin>100kΩ),
20
AI5-
Differential input
0...20mA with Rin = 100Ω
22
AI6+
Differential input
Differential input:
± 10V (Rin>100kΩ),
24
AI6-
Differential input
0...20mA with Rin = 100Ω
26
AO3
Analog Output
± 10V, 10mA Rlast min = 1k
28
AGND
Analog GND
0V, reference for analog
outputs
30
REF-
Reference voltage -10V
- 10V, short-circuit protected,
30mA,
32
REF+
Reference voltage +10V
+ 10 V short-circuit protected,
30mA,
Tab. 2 Pin assignment of edge connector Row b
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Installing the HACD 2
Row z
Pin
Description
Type
2
MA+
Solenoid a +
4
MA-
Solenoid a -
6
MB+
Solenoid b +
8
MB -
Solenoid b -
10
Shield
Shield
internally connected with z 20
12
L1O-
LVDT valve pin 2
Supply GND
14
L1I-
LVDT valve pin 4
Actual value GND
16
L1I+
LVDT valve pin 3
Actual value signal
18
L1O+
LVDT valve pin 1
Supply signal (f=5 Khz
VSS=10V)
20
Ground
System ground
22
DO 3
Discrete output
Ub-3V, 30mA, short-circuit
protected
24
DO 4
Discrete output
Ub-3V, 30mA, short-circuit
protected
26
DO 5
Discrete output
Ub-3V, 30mA, short-circuit
protected
28
DO 6
Discrete output
Ub-3V, 30mA, short-circuit
protected
30
UB
Supply voltage
UB + 24V DC
UB(t) max + 35V DC
UB(t) min + 21V DC
32
LO
Supply GND
0V
Tab. 3 Pin assignment of edge connector Row z
Specification
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2 Installing the HACD
Row f
Pin
Description
Type
Specification
2
DO 7
Discrete output
Ub-3V, 30mA, short-circuit
protected
4
SSI Clk +
Clock output
SSI encoder
5V Signal RS-485 compatible
6
SSI Clk -
Clock output
SSI encoder
5V Signal RS-485 compatible
8
SSI Data+ /
INC Ua1
Data input
SSI encoder
5-24V Signal
10
SSI Data - /
INC /Ua1
Data input
SSI encoder
5-24V Signal
12
Ua2
Data input
Incremental encoder
14
/Ua2
Data input
Incremental encoder
16
Ua0
Data input
Incremental encoder
18
/Ua0
Data input
Incremental encoder
20
L2O-
n. c.
22
L2I-
n. c.
24
L2I+
n. c.
26
L2O+
n. c.
28
GND_CAN
CAN Bus reference
CAN Specification
30
CANL
CAN Bus In-/Output
CAN Specification
32
CANH
CAN Bus In-/Output
CAN Specification
Tab. 4 Pin assignment of edge connector Row f
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Installing the HACD 2
2.6
Installation Local Bus
The local bus is used to connect the individual amplifier cards of the HACD family.
Data can be sent from one HACD to another or Bodac can use the local bus to communicate with any card on the bus without physically changing the connection.
Up to 32 cards can be connected. Each amplifier must be assigned a clear bus address.
The connection is established using a CAN protocol with a baud rate of 250kbit. The
maximum length of the most distant amplifier cards must not exceed 280m. Moreover,
the maximum length of the branch lines of 1 m must be observed.
Fig. 3 Schematic structure of “Local Bus“
Data is to be transmitted via a shielded twisted-pair cable.
Two bus terminating resistors of 120 Ohm are required.
Using Local Bus to send data from one HACD to another takes priority
over communicating with any other card via Bodac.
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3 Startup of the HACD Controller Card
3
Startup of the HACD Controller Card
3.1
Preparing for Use
The startup procedure for the HACD controller card depends on a variety of factors
that are determined by the individual application. For this reason, only the basic
startup steps are described in this manual.
Preparing the controller card for use:
¾
Carefully check cabling.
¾
Apply power to the HACD controller card.
Fig. 4 Front panel of the HACD Controller Card
9
The controller card performs an internal function test.
9
The display on the controller card shows the manufacturer name and version
number in scrolling text (when powered up)
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Startup of the HACD Controller Card 3
3.2
Installing BODAC software
BODAC software (ordering code SYS-HACD-BODAC-01) can download via Internet.
This software is used for initial startup and as a convenient configuration and monitoring tool for the controller card. BODAC can be used to configure the settings and
parameters for optimal operation of the HACD controller card. The connected HACD
card configures the function, menus and program windows in BODAC. This makes
using the software easy.
Installation Requirements
Hardware
Software
100% IBM compatible PC with the following minimum requirements:
„
200 MHz Pentium processor (or equivalent)
„
32 MB working memory (RAM)
„
VGA graphics card, minimum resolution: 800x600 pixels
„
Hard drive with minimum 2 MB available space
„
CD-ROM drive
„
Mouse
„
Available serial port
„
freie serielle Schnittstelle
„
Operating system: Windows™ 2000 / XP.
If the hardware/software requirements are met, you can install BODAC as described
in the next section.
BODAC Setup
To start the installation of BODAC, execute the “Setup.exe“ file.
Installing BODAC software:
¾
Insert the CD-ROM and locate the file “Setup.exe“.
¾
Double-click on “Setup.exe“.
9
The setup program will load and display a start screen.
¾
To run Setup, follow the instructions on the screen.
9
BODAC software will then be installed.
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3 Startup of the HACD Controller Card
3.3
Initial startup with BODAC
„
After installing the HACD controller card in a rack, as described in section2.4,
"Installing the card", and all initial steps have been completed properly, the card
startup is ready.
„
Before proceeding with the following steps, be sure that the following requirements have been met:
„
Serial interface cable is available
„
A serial port on the PC is available
„
BODAC software is installed.
Proceed with the initial startup:
¾
Connect serial cable (S/N 0776897) to the connector on the HACD card.
¾
Plug serial cable into the serial port (COM) on the PC.
9
The HDAC card and PC are now connected.
¾
Start the BODAC software.
9
Perform the software-side startup as described in the “Starting up the HACD
Control Card and Operation of the BODAC Software” document.
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HACD Operation 4
4
HACD Operation
4.1
Display/Input Keys and Connectors on the Front Panel
You can use the display, input keys and connectors on the front panel of the HACD to
check parameters and settings, attach diagnostic instruments and connect the card to
a PC.
The following illustration shows an overview of the display, input keys and connectors
on the front panel.
Fig. 5 Display, input keys and connectors on the control card
Display
The display is four characters in length. Messages that exceed four characters are
displayed as a scrolling display.
When parameters are displayed, the negative or positive sign is indicated by the “+”
and “-“ LEDs.
LEDs for Discrete I/O
The input LEDs indicate the state of the discrete input signals. The output LEDs show
the state of discrete outputs from the controller card. When a signal is present on a
discrete I/O, the associated LED will illuminate.
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4 HACD Operation
Serial Port
The serial port on the front panel is configured as a standard RS-232 port using a 9pin D-Sub female connector. A standard 9 pin serial data cable is used to connect the
serial port to a PC.
Profibus Port
(optional)
The Profibus DP V0 interface on the faceplate is a 9-pin D-Sub connector as descibed
in the Profibus norm (EN 50170 Part 2). It connects the HACD card with a Profibus
DP master. The connector is only available on HACD cards with optional Profibus.
Pin
Description
3
RxD/TxD-P (B-Line)
5
DGND
6
VP (5V)
8
RxD/TxD-N (A-Line)
The address setting is done via a DIL switch on the Profibus daughterboard of the
HACD before the start up. Allowed values are between 1 and 126. Typically the DP
master will have the address 0 to 2. Therefore it is advisable to choose an address
higher than 2 for the HACD. Below is an example for the setting of the address 40:
LSB
1
2
4
8
16 32
MSB
64
↑ ON
↓ OFF
1
2
3
4
5
6
7
8
Not used, has to
be “OFF”
The address will only be read during the card powers up. A change of
the address will be done consequently only after a power reset of the
card.
When you distribute the address you have to take care that each
Profibus station has it’s own explicid and once-only address.
For further information about the handling of Profibus parameters with the HACD see
the documentation “RD 30 143-01-Z” (part of the BODAC package).
Buttons
Four buttons are located on the front panel of the card. The functions of these buttons
are described in detail in section 4.4,"Performing operations”.
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HACD Operation 4
4.2
Diagnostics Test Jacks
The diagnostic test jacks on the front panel of the card can be used to connect external test instruments. Two analog voltage signals are available to perform measurements.
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Installation and Operation | RE 30143-B/08.07
4 HACD Operation
4.3
Menu Tree for Setup and Parameters
The following contains an overview of the menus that can be selected using the buttons on the HACD controller card. Shown are the parameters and settings that are
available
An overview of the items listed below are shown on the following pages:
„
Menu tree "Parameter Part 1"
„
Menu tree "Parameter Part 2"
„
Menu tree "Parameter Part 3"
„
Menu tree "Setup"
„
Menu tree "Valve Menu"
„
Menu tree "Analog I/O Part 1"
„
Menu tree "Analog I/O Part 2"
„
Menu tree "Digital I/O“
„
Menu tree "SSI Configuration“
„
Menu tree "Test Jacks Part 1“
„
Menu tree "Test Jacks Part 2“
„
Menu tree "Faults"
For a detailed description of the settings and parameters, please refer to document:
“Starting up the HACD Control Card and Operation of BODAC Software”.
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HACD Operation 4
Level 1
Level 2
Level 3
Level 4
Level 5
Level 6
Parameter
Use "ENTER"
to go to menu
Block 1~32
Loop 1
Command parameter
Command
Unit
[-50000.00~+50000.00] Units
Velocity+
Unit/s
[0~5000.0] Units/sec
Velocity-
Unit/s
[0~5000.0] Units/sec
S-Ramp Start
s
[0.00~60.00] Sec
S-Ramp end
s
[0.00~60.00] Sec
Control parameter
P
[0.00~99.90]
I
ms
[0~30000] ms
I on |CMD-LFB|<
Unit
[0.00~50000.00] Units
I on |CMD-LFB| >
Unit
[0.00~50000.00] Units
DT1
Hz
[0~640] Hz
DT1(LFB1)
Hz
T1 Lag
Hz
Feed Fwd
%
[0~640] Hz
[0~640] Hz
[0.00~1.00]
Loop 2
Commad Parameter
Command
Unit
[-50000.00~+50000.00] Units
Velocity+
Unit/s
[0~5000.0] Units/sec
Velocity-
Unit/s
S-Ramp Start
s
S-Ramp end
s
[0~5000.0] Units/sec
[0.00~60.00] Sec
[0.00~60.00] Sec
Fig. 6 Menu tree "Parameter Part 1"
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Bosch Rexroth AG | Hydraulics
Installation and Operation | RE 30143-B/08.07
4 HACD Operation
Level 1
Level 2
Level 3
Level 4
Level 5
Level 6
Control parameter
P
[-50000.00~+50000.00] Units
I
ms
[0~5000.0] Units/sec
I on |CMD-LFB|<
Unit
[0~5000.0] Units/sec
I on |CMD-LFB| >
Unit
[0.00~60.00] Sec
DT1
Hz
[0~640] Hz
DT1(LFB2)
Hz
T1 Lag
Hz
Feed Fwd
%
[0~640] Hz
[0~640] Hz
[0.00~1.00]
Link/Controller
Loop 1
Active damping
Gain
[0.0~255.9]
Damping D
Hz
[0~640] Hz
Units to 100% OUT
[0.0~50000.0]
Loop 2
Active damping
Gain
[0.0~255.9]
Damping D
Hz
[0~640] Hz
Units to 100% OUT
[0.0~50000.0]
Fig. 7 Menu tree "Parameter Part 2"
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HACD Operation 4
Level 1
Level 2
Level 3
Level 4
Level 5
Output
Gain+
[-10.00~+10.00]
Gain[-10.00~+10.00]
Offset %
[-100.00~+100.00]
Overlap
Step+ %
[0.00~+100.00]
Step-
%
[0.00~+100.00]
Deadband
%
[0.00~+100.00]
Residual
Residual+
%
Residual-
%
[0.0~+100.0]
[0.0~+100.0]
Accuracy window
%
[0.0~+100.0]
Limit+ %
[0.0~+100.0]
Limit-
%
[0.0~+100.0]
Constants
CON 1
[-50000.00~+50000.00] Units
CON 2
[-50000.00~+50000.00] Units
CON 3
[-50000.00~+50000.00] Units
CON 4
[-50000.00~+50000.00] Units
CON 5
[-50000.00~+50000.00] Units
CON 6
[-50000.00~+50000.00] Units
CON 7
[-50000.00~+50000.00] Units
CON 8
[-50000.00~+50000.00] Units
Configure *
Zeropoint valve %
[-12.0~+12.0]
Fig. 8 Menu tree "Parameter Part 3"
Level 6
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Bosch Rexroth AG | Hydraulics
Installation and Operation | RE 30143-B/08.07
4 HACD Operation
Level 1
Level 2
Level 3
Level 4
Level 5
Level 6
Setup
Press “ENTER + ESC“ Language
to go to the configuration menu
German
English
Fieldbus
ID
[1~63]
Local Bus
ID
[1~32]
Display
Text
C1-1
C1-2
C2-1
C2-2
C3-1
C3-2
FB1-1
FB1-2
FB2-1
FB2-2
FB3-1
FB3-2
C1
C2
C3
FB1
FB2
FB3
LC1
LC2
LFB1
LFB2
LO1
LO2
OUT1
OUT2
Act. Valve *
Fig. 9 Menu tree "Setup"
* only for VT-HACD-1-1x/v0/1-P-1
There has to be an obligatory reinitialization of the controller card after
changing a bus ID. Toggle the card when the changes are written successfully to the memory.
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HACD Operation 4
Level 1
Level 2
Level 3
Level 4
Valve Menu *
Press “ENTER + ESC“ Off
to go to the configuration menu
Direct
Valve o. l.**
Valve c. l.***
4WRE
NG6 - 2x
NG10 - 2x
Fig. 10 Menu tree "Valve Menu"
*
only for VT-HACD-1-1x/v0/1-P-1
**
only for daughterboard TSPD
***
only for daughterboard TRPD
Level 5
Level 6
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4 HACD Operation
Level 1
Level 2
Level 3
Level 4
Level 5
Analog I/O
Press “ENTER + ESC“ Inputs
to go to the configuration menu
AI1
Type
+/-10 Volts
0~10 Volts
0~20 mA
4~20 mA
Range
+/-100 %
0~100 %
Min. Value V
[-11.00~+11.00] V
Min. Value mA
[-2.00~+22.00] mA
Max. Value V
[-11.00~+11.00] V
Max. Value mA
[-2.00~+22.00] mA
Min. Fault V
[-11.00~+11.00] V
Min. Fault mA
[-2.00~+22.00] mA
Max. Fault V
[-11.00~+11.00] V
Max. Fault mA
[-2.00~+22.00] mA
Max Unit
[0.0~+50000.0]
AI2
…
…
AI3
…
…
AI4
…
…
AI5
…
…
AI6
…
…
Outputs
AO1
Type
+/-10 Volt
[0~+10] Volt
[0~+20] mA
[+4~+20] mA
Range
+/-100 %
[0~+100] %
Offset
[-100.0~+100.0]
Fig. 11 Menu tree "Analog I/O Part 1"
Level 6
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HACD Operation 4
Level 1
Level 2
Level 3
Level 4
Level 5
Level 6
AO2
Range
+/-100 %
[0~+100] %
Offset
[-100.0~+100.0]
Fig. 12 Menu tree "Analog I/O Part 2"
Level 1
Level 2
Level 3
Level 4
Level 5
Digitale I/O
Press “ENTER + ESC“ Inputs
to go to the configuration menu
Binary Mode
Off
On
Enable Set OK
Off
On
Outputs
DO1
Window
[-50000.00~+50000.00]
Debounce
[+0.01~+60.00] sec
DO2
…
…
DO3
…
…
DO4
…
…
DO5
…
…
DO6
…
…
DO7
…
…
Fig. 13 Menu tree "Digital I/O“
Level 6
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4 HACD Operation
Level 1
Level 2
Level 3
Level 4
Level 5
Level 6
Level 5
Level 6
SSI Configure
Press “ENTER + ESC“ Nb. of Bits
to go to the configur-
[8~31]
ation menu
Data Type
Binary
Gray
Resolution [ct/Unit]
[0.00~+10000.00]
Offset [Unit]
[-400000.00~+400000.00]
Fig. 14 Menu tree "SSI Configuration“
Level 1
Level 2
Level 3
Level 4
Test Jacks
Press “ENTER + ESC“ X1
to go to the configuration menu
Signal
C1-1
C1-2
C2-1
C2-2
C3-1 *
C3-2 *
FB1-1
FB1-2
FB2-1
FB2-2
FB3-1 *
FB3-2 *
C1
C2
C3 *
FB1
FB2
FB3 *
LC1
LC2
LFB1
LFB2
LO1
LO2
OUT1
OUT2
Act. Valve *
Fig. 15 Menu tree "Test Jacks Part 1“
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HACD Operation 4
Level 1
Level 2
Level 3
Level 4
Range
+/-100 %
[0~+100] %
X2
Signal
C1-1
C1-2
C2-1
C2-2
C3-1 *
C3-2 *
FB1-1
FB1-2
FB2-1
FB2-2
FB3-1 *
FB3-2 *
C1
C2
C3 *
FB1
FB2
FB3 *
LC1
LC2
LFB1
LFB2
LO1
LO2
OUT1
OUT2
Act. Valve *
Range
+/-100 %
[0~+100] %
Unit to 100% Out
[-50000.00~50000.00]
Fig. 16 Menu tree "Test Jacks Part 2“
Level 5
Level 6
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Bosch Rexroth AG | Hydraulics
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4 HACD Operation
Level 1
Level 2
Level 3
Level 4
Faults
Press “ENTER + ESC“ Analog Inputs
to go to the configuration menu
AI1
Off
Stop
Flag
AI2
…
AI3
…
AI4
…
AI5
…
AI6
…
Block Timeout
Off
Stop
Flag
SSI Fault
Off
Stop
Flag
Block Fault
Off
Stop
Flag
Loop Fault 1
Mode
Off
Stop
Flag
Window
[-50000.00~+50000.00]
Debounce
[+0.01~+60.00] sec
Loop Fault 2
Mode
Off
Stop
Flag
Window
[-50000.00~+50000.00]
Debounce
[+0.01~+60.00] sec
Fig. 17 Menu tree "Faults"
Level 5
Level 6
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HACD Operation 4
4.4
Display/Input Key Operations
All operations can be performed directly on the card using the "UP", "DOWN", "ENTER" and "ESCAPE" keys.
The keys are especially useful for quickly and easily checking, changing
or correcting parameters and settings.
Always use BODAC software for the initial startup before placing the card
in service.
Before making any changes to parameters or settings, familiarize yourself with the
menu structure of the card. This can be found in section 4.3: "Menu tree for settings
and parameters".
Key functions:
z
UP
z
DOWN
Pressing the "UP" key moves in the upward direction, within the selected level, to
available menu items. (for an overview, see section 4.3: "Menu tree for settings and
parameters")
Pressing the "DOWN" key moves in the downward direction, within the selected level,
to available menu items (for an overview, see section 4.3: "Menu tree for settings
and parameters").
Change menu mode:
z
ENTER
Press the "ENTER" key for 2 seconds or longer, to switch to configuration mode –
"EDIT Parameters".
Change menu level:
Press the “ENTER“ key to take you one level lower in the menu structure, or confirms
an entered value.
Note: The entered value will be stored in memory by returning to level 0 (displaying the manufacturer’s name).
The process of storing the data will take about a minute. During this time do not
cut off the current supply of the card, otherwise your changes won’t be saved in
the memory.
z
ESCAPE
z
+
z
ENTER
ESCAPE
Pressing the "ESCAPE" key takes you one level higher in the menu structure.
Pressing the “ENTER“ and “ESCAPE“ keys simultaneously opens the configuration
menu.
The configuration menu is structured in levels. The first level contains main categories, below which are additional sub-categories and settings. Depending on the entry
selected, a main category may have up to 4 sub-levels.
The following figure illustrates the menu level structure.
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Installation and Operation | RE 30143-B/08.07
4 HACD Operation
Ebene 1
Ebene 2
Ebene 3
Ebene 4
Ebene 5
one Level down:
ENTER
ENTER
ENTER
ENTER
one Level up:
ESCAPE
ESCAPE
ESCAPE
ESCAPE
Parameter
Block 1-32
Loop 1
parameter
command
HACD_HW_EN_M9
Fig. 18 Example of the menu levels in configuration mode
Changing from Run Mode to Configuration Mode – "EDIT Parameters":
The card must be in run mode.
The display will show scrolling text to display the manufacturer’s name, the software
version for the controller, or a custom configured text string.
¾
Press and hold "Enter“ and "ESCAPE“ simultaneously for at least 2 seconds
(except when in "EDIT Parameter” mode, see above) until the dislplay reads
"Setup”.
9
The controller card is now in "EDIT Parameter" mode.
Changing from Run Mode to Configuration Mode:
The card must be in run mode.
The display will show scrolling text to display the manufacturer’s name, the software
version for the controller, or a custom configured text string.
9
Press and hold "Enter" and "ESCAPE" simultaneously for at least 2 seconds
(except when in "EDIT Parameter“ mode, see above) until the display reads “Setup“.
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HACD Operation 4
To exit Configuration Mode
As an example, the second level of the “Setup” menu is shown.
The display on the controller card shows the option “Sprache/Language“.
¾
Press “ESCAPE”.
9
The display is scrolling “Setup“.
¾
Press “ESCAPE”.
9
The display will show scrolling text to display the manufacturer’s name, the software version for the controller, or a custom configured text string
If while in Configuration Mode no entry is made within one minute, the
controller card will automatically return to successively higher menu
levels until Run Mode is reached.
The HACD Control Card is fully operational in Configuration Mode.
To change a parameter using the input keys
As an example, the parameter "Max. Value" (see Fig. 11 Menu tree "Analog I/O Part
1"–Inputs – AI1) is shown. In this case, set the parameter to: “+10 Volts“.
The card is now in Run Mode.
The display will show scrolling text to display the manufacturer’s name, the software
version for the controller, or a custom configured text string.
WARNING!
When changing parameters using the input keys, hardware inputs
are configured even when the discrete input “Enable” is active.
caution:
Do not change any analog input from voltage to current or current
to voltage when active.
Changing the analog inputs configuration may result in incorrectly
interpreted values.
This can result in uncontrolled system operation and damage
to the machine!!
¾
Press and hold the “Enter“ and “ESCAPE“ keys simultaneously for at least 2
seconds until the display reads “Setup“.
9
The card is now in Configuration Mode.
¾
Press the “UP” or “DOWN” keys to select “Analog I/O”.
¾
Press “ENTER”.
9
The card is now at the second level of the Configuration Menu, “Analog I/O“
mode.
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Bosch Rexroth AG | Hydraulics
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4 HACD Operation
¾
Press the “UP” or “DOWN” keys to select “Inputs”.
¾
Press “ENTER”.
9
The menu entry Analog Input 1 ("AI1") is shown.
¾
Press “ENTER”.
¾
Press the “UP” or “DOWN” keys to select “Max. Value”.
¾
Press “ENTER”.
9
The current value is shown.
¾
Press “UP”.
This creates a positive sign. Pressing „DOWN“ gives the value a negative sign.
¾
Press “UP” until "1" is displayed.
¾
Press “ENTER”.
¾
Press “UP” until "0" is displayed.
¾
Press “ENTER”.
¾
Press “UP” until "." is displayed.
¾
Press “ENTER”.
¾
Press “UP” until "0" is displayed.
¾
Press “ENTER”.
¾
Press “UP” until "0" is displayed.
¾
Press “ENTER”.
9
The parameter “Max. Value“ 10 Volts is now entered and displayed.
¾
Exit the Configuration Menu by pressing “ESCAPE" five times.
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HACD Operation 4
To show setpoints/feedback values on the display run mode
In this example, the signal "OUT1"(Fig. 9 Menu tree "Setup") will be used.
The card should be in Run Mode.
The display will show scrolling text to display the manufacturer’s name, the software
version for the controller, or a custom configured text string.
¾
Press and hold the “ENTER“ and “ESCAPE” keys for at least 2 seconds until the
display reads “Setup“.
9
The card is now in Configuration Mode.
¾
Press “ENTER”.
9
The card is at the second level of the Configuration Menu.
¾
Press the “UP” or “DOWN” keys to select “Display”.
¾
Press “ENTER”.
9
Menu entry "Text" is displayed.
9
Press the “UP” or “DOWN” keys to select "OUT1".
¾
Press “ENTER”.
9
The signal "OUT1" is displayed when the card returns to Run Mode.
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Installation and Operation | RE 30143-B/08.07
5 Diagnostics
5
Diagnostics
5.1
Diagnostic Options on the HACD Controller Card
Diagnostic terminal
The diagnostic test jacks on the front panel of the HACD controller card (see section
4.2) provide two analog outputs with the following ratings:
„
X1, 10 Volts for test equipment having Ri 〈 100 kς
„
X2, 10 Volts for test equipment having Ri 〈 100 kς
„
COM, ground
Test Jack "X1"
On test jack “X1“ the value of analog output “AO3“ is available. The signal is selected
via the display menu (Fig. 11 Menu tree "Analog I/O Part 1").
Test Jack "X2“
Using the menu, the signal to be measured can be selected for analog output “AO3“.
A list of available signals is shown in (Fig. 12 Menu tree "Analog I/O Part 2").
Display
indication when an error occurs
During initial startup, BODAC software can be used to select the action of the controller when an error occurs (available in the “Error“ screen). If the controller card detects
an error, which has been configured with BODAC software, the error will be displayed
on the HACD controller card.
If the control card detects an error configured with BODAC software,
respond as follows:
The display will flash "ERR" (Error) on the controller card!
Press “ENTER” to display the error message and clear the error.
The procedure for selecting the action desired when an error occurs can be found in
the document “Starting up the HACD Control Card and Operation of the BODAC
Software".
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Diagnostics 5
5.2
Diagnostics Using BODAC
The BODAC software includes additional detailed diagnostics capabilities.
The “Motion Data” screen and the “Status” screen display the current status of the
controller card and of the connected sensors and devices.
Motion Data Screen
Status Screen
The Motion Data screen displays the internal control signal values in the controller
card. This provides a quick overview of the process status and values.
The Status screen is used to display the status of the controller card. Each entry will
display either “OK”, “WARNING” or “ERROR" as a value.
For additional information on the Motion Data screen and the Status screen, refer to
document "Starting up the HACD Control Card and Operation of the BODAC Software".
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6 Detecting Errors
6
Detecting Errors
6.1
Error Messages
Error message
Description
+/- 10V voltage
Reference voltage +10V (b32) or reference voltage –10V
(b30) outside allowable tolerances.
Supply voltage
Supply voltage Ub (z30) outside allowable tolerances
21...35V.
DO1~DO8 short circuit Short circuit on one or more of the 8 discrete outputs.
Checksum
Checksum error in program or data memory (Flash or
EEprom)
Memory error
Error in working memory (RAM)
Version error
Versions of the individual program parts are not compatible
(can occur only if updates to firmware were made)
Analog Input AI1
The signal on analog input AI1 is outside the valid signal
range (adjustable, see Fig. 17 Menu tree "Faults").
Analog Input AI2
The signal on analog input AI2 is outside the valid signal
range (adjustable, see Fig. 17 Menu tree "Faults").
Analog Input AI3
The signal on analog input AI3 is outside the valid signal
range (adjustable, see Fig. 17 Menu tree "Faults").
Analog Input AI4
The signal on analog input AI4 is outside the valid signal
range (adjustable, see Fig. 17 Menu tree "Faults").
Analog Input AI5
The signal on analog input AI5 is outside the valid signal
range (adjustable, see Fig. 17 Menu tree "Faults").
Analog Input AI6
The signal on analog input AI6 is outside the valid signal
range (adjustable, see Fig. 17 Menu tree "Faults").
Block Timeout
The block time value for a block has timed out, without
another block being called.
SSI error
Cable fault on SSI encoder
Block error
Ambiguous block triggers
LC1 <> LFB1
A control difference between setpoint (LC1) and feedback
(LFB1). The difference value (window) and time delay (delay) can be set in the controller card
LC2 <> LFB2
A control difference between setpoint (LC2) and feedback
(LFB1). The difference value (window) and time delay (delay) can be set in the controller card
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Detecting Errors 6
6.2
Changing fuses
The controller card is protected against overload by means of a fuse. The fuse is the
following type:
F / 4A / 250V
NOTE!
The fuse is defective and must be replaced!
The fuse has opened due to mechanical damage or a product
defect.
In this case, replace the fuse with a new one of the type indicated
above.
The fuse has opened due to external connections, IE: externally
connected components or wiring connected to the controller card
have faulted.
In such cases, diagnose and correct the problem that caused the
fuse to open.
Only then replace the fuse with a new one.
Replacing the fuse on the HACD Control Card:
¾
Remove HACD controller card the card holder (reverse of the procedure described in section 2.4, GeneralCard Installation)
¾
Gently remove the fuse from the fuse holder (see Fig. 19).
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Installation and Operation | RE 30143-B/08.07
6 Detecting Errors
HACD_HW_EN_6-2
Fig. 19 Fuse on the HACD Controller Card
¾
Use a suitable test device to check the fuse. (continuity test)
¾
If the fuse is defective, replace it with the same type.
¾
Reinstall the HACD controller card and perform a functional test.
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Index 7
7
Index
Action symbol .......................................................................6
Analog GND .......................................................................14
Analog input .......................................................................14
BODAC setup routine.........................................................19
BODAC software ................................................................19
CAN Bus in-/output.............................................................13
Change parameter .............................................................39
Characters............................................................................6
compatible ..........................................................................13
Configuration mode ............................................................37
Control card
Installation ......................................................................12
Diagnostics terminal .....................................................23, 40
Diagnostics using BODAC..................................................41
Differential inputs..................................................................9
Digital input.........................................................................13
Display ...............................................................................21
DOWN ................................................................................35
Drives
Electromechanical and electrohydraulic ...........................5
EC Directive 89/392/EWG (Machine Directive) ....................8
Edge connector ..................................................................13
EMC Regulations .................................................................8
ENTER ...............................................................................35
Error conditions ..................................................................40
Error messages ..................................................................42
ESCAPE.............................................................................35
Front panel .........................................................................12
Fuse ...................................................................................43
HACD .................................................................................40
Initial startup .......................................................................40
Installation ............................................................................9
Installation requirements ....................................................19
Keys ...................................................................................35
Language ...........................................................................28
LED´s for digital in-/.outputs ...............................................21
Local Bus............................................................................17
Menu tree
"Analog I/O Part 1" .........................................................30
"Parameter Part 1"..........................................................25
"Parameter Part 2"..........................................................26
"Parameter Part 3"..........................................................27
"Setup" ...........................................................................28
"Valve Menu" ..................................................................29
“Digital I/O“ .....................................................................31
“Faults” ...........................................................................34
“SSI Configuration” .........................................................32
“Test Jacks Part 1” .........................................................32
“Test Jacks Part 2” .........................................................33
”Analog I/O Part 2” .........................................................31
Noise sources.......................................................................9
Parameter changing ...........................................................37
Password............................................................................28
Power cables........................................................................9
Reference voltage ..............................................................14
46/48
Bosch Rexroth AG | Hydraulics
Installation and Operation | RE 30143-B/08.07
7 Index
Result symbol .......................................................................6
Run mode...........................................................................36
Running text ...........................................................36, 37, 39
Safety fuse .........................................................................43
Safety requirements .............................................................5
Sensor lines..........................................................................9
Serial port ...........................................................................22
Shield .................................................................................10
Shielding.............................................................................10
Supply GND .......................................................................15
Supply voltage....................................................................15
Symbols................................................................................6
System ground ...................................................................10
Transport ............................................................................11
Troubleshooting..................................................................10
UP ......................................................................................35
Warning symbol
Equipment damage ..........................................................6
Hazard potential, electrical current ...................................6
Hazard potential, general .................................................6
RE 30143-B/08.07 | Installation and Operation
Hydraulics | Bosch Rexroth AG
47/48
Index 7
I
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
[email protected]
www.boschrexroth.com
© This document, as well as the
data, specifications and other
information set forth in it, are the exclusive property of Bosch Rexroth
AG. It may not be reproduced or
given to third parties without its
consent.
The data specified above only
serve to describe the product. No
statements concerning a certain
condition or suitability for a certain
application can be derived from
our information. The information given does not release the user from
the obligation of own judgment and
verification. It must be remembered
that our products are subject to a
natural process of wear and aging.
Printed in Germany
RE 30143-B/08.07
Replaces: 04.07
VT-HACD-DPQ
Digital Controller for electro-hydraulic
Injection Molding Machines
Installation and Operation
RE 30146-B/08.07
Replaces: 11.06
Contents
Contents
1
GENERAL....................................................................................................................................................................... 4
1.1
ABOUT THIS MANUAL ................................................................................................................................................ 4
Additional Documentation ................................................................................................................................................ 5
Characters and Symbols ................................................................................................................................................... 5
1.2
SCOPE OF SUPPLY ...................................................................................................................................................... 6
1.3
REQUIREMENTS ......................................................................................................................................................... 6
2
INSTALLING THE HACD-DPQ.................................................................................................................................. 8
2.1
SAFETY REQUIREMENTS ............................................................................................................................................ 8
Proper Use ........................................................................................................................................................................ 9
Personnel Selection and Qualification.............................................................................................................................. 9
Design Changes and Electrical Installation ................................................................................................................... 10
2.2
REPAIR AND TROUBLESHOOTING ............................................................................................................................. 11
2.3
TRANSPORT, STORAGE AND HANDLING THE CONTROLLER CARD ........................................................................... 12
2.4
CARD INSTALLATION ............................................................................................................................................... 13
2.5
EDGE CONNECTOR TERMINALS AND PIN ASSIGNMENTS ON THE ............................................................................. 14
3
STARTUP OF THE HACD-DPQ CONTROLLER CARD ...................................................................................... 18
3.1
PREPARING FOR USE ................................................................................................................................................ 18
3.2
INSTALLING BODAC SOFTWARE ............................................................................................................................. 19
Installation Requirements ............................................................................................................................................... 19
BODAC Setup ................................................................................................................................................................. 19
3.3
INITIAL STARTUP WITH BODAC .............................................................................................................................. 20
4
HACD-DPQ OPERATION .......................................................................................................................................... 22
4.1
4.2
4.3
4.4
5
DIAGNOSTICS............................................................................................................................................................. 33
5.1
5.2
6
DIAGNOSTIC OPTIONS ON THE HACD-DPQ CONTROLLER CARD ............................................................................ 33
DIAGNOSTICS USING BODAC ................................................................................................................................. 33
DETECTING ERRORS ............................................................................................................................................... 35
6.1
6.2
7
DISPLAY/INPUT KEYS AND CONNECTORS ON THE FRONT PANEL............................................................................. 22
DIAGNOSTICS TEST JACKS ....................................................................................................................................... 23
MENU TREE FOR SETUP AND PARAMETERS ............................................................................................................. 23
DISPLAY/INPUT KEY OPERATIONS ........................................................................................................................... 28
ERROR MESSAGES ................................................................................................................................................... 35
CHANGING FUSES ..................................................................................................................................................... 35
INDEX............................................................................................................................................................................ 39
Installation and Operation
3
1 General
1
General
1.1 About this Manual
Before installing or operating your HACD-DPQ Controller card for
the first time, you should read this Manual. Please note the safety
requirements described in section 2.1
Persons involved with the start-up and operation of the controller
card should have proper training on the installation and operation
of this type of equipment.
This manual is intended to inform you about the functions of this
controller card and its intended use.
The Manual contains important safety instructions on proper
installation and operation of the controller card. Observing these
instructions will help you:
■
avoid hazards and dangers
■
minimize repair costs and downtime
■
increase the useful life and reliability of the controller card.
Additionally, please observe all regulations that are in effect in the
country and/or community to prevent accidents and to protect the
environment.
This manual only describes the installation and operation of the
controller card. Information about starting up the controller card
using BODAC software is located in a separate document:
“Operation of the BODAC Software and Starting up the HACD-DPQ
Control Card”. A list of documentation for the HACD-DPQ can be
found in the “Additional Documentation" section.
Version: 1.1
4
Installation and Operation
1 General
Additional Documentation
Included with this manual is the document “HACD-DPQ Digital
Controller for Hydraulic Clamp Units".
It contains:
■
RE sheet "RE 30 146" in paper form.
■
Document RE 30 146-B: "Installation and Operation " (the
document you read, included with the shipment).
■
Document RE 30 146-01-B "Start-up and Operation" as online
help (part of the BODAC package)
■
Document RE 30 146-02-Z "Start-up CANopen Interface"as
online help for description of the CANopen interface (part of the
BODAC package)
■
Internet: www.boschrexroth.com/hacd
Characters and Symbols
The following characters and symbols are used in the manual:
Action symbol: The text following this symbol describes actions.
These should be performed, from top to bottom, in the given
order.
9 Result symbol: The text following this symbol describes the
results of an action.
Following this symbol you will find notes and useful tips for
optimal use of the controller card.
Warning symbols
Special safety notes are provided at the relevant locations. These
are indicated by the following symbols.
General hazard potential
Indicates a potentially hazardous condition which, if not
avoided, could result in death or serious injury.
If the hazard source can be specifically indicated, the
corresponding pictogram will be used.
Electrical current hazard
This symbol refers to a hazardous condition caused by
electrical current which, if not avoided, could result in
death or serious injury.
Installation and Operation
5
1 General
Equipment damage
This symbol pertains to actions which could result in
damage to equipment.
1.2 Scope of Supply
The equipment is packed in anti-static packaging to protect the
controller card from electrostatic discharge. Observe instructions on
the top side of the packaging.
Included in the shipment:
■
HACD-DPQ Controller Card
■
RE sheet RE 30 146-B
1.3 Requirements
Mounting the controller card in a 19” rack:
■
VT 19 101
■
VT 19 102
■
VT 19 103
■
VT 19 110.
described in datasheet RE 29 768, or mounted in a card holder
■
VT 3002-2x/G64
described in datasheet RE 29 928.
The card holder should be used only inside a control cabinet, as
there is no protection from accidental contact.
If no power is provided by the user, the following power supply is
available as an option:
■
VT-NE30
described in datasheet RE 29 929.
6
Installation and Operation
1 General
Notes
Installation and Operation
7
2 Installing the HACD-DPQ
2
Installing the HACD-DPQ
2.1 Safety Requirements
Operate the HACD-DPQ controller card only if it is not damaged
and is in proper operating condition and is applied for its intended
purpose. Observe all safety and hazard instructions in the included
documentation.
When faults occur, which compromise safety and result in changes
in operating conditions, shut down the controller card immediately
and notify responsible personnel.
Fault free and safe running of the controller card assumes
appropriate transport, storage and installation, as well as proper
startup and operation.
The HACD-DPQ Control Card has been built using the latest
technology, and in accordance with recognized safety standards.
Nevertheless, operation may result in hazard to persons or property
if:
■
The HACD-DPQ Controller Card is not used properly.
(see page 9, Proper Use)
■
The HACD-DPQ Control Card is not installed, commissioned
and operated by qualified persons.
■
Changes or modifications are made to the HACD-DPQ controller
card.
■
Safety requirements and safety notes are not observed.
The HACD-DPQ controller card is intended for industrial use.
The card must not be operated until it has been determined that the
system in which the controller card is installed, meets all applicable
standards and safety regulations for the application.
In European countries: EC Directive 89/392/EWG (Machine
Directive)
Operation is permitted only when applicable EMC regulations for
the application are met.
Adherence to limits defined by regulations and standards are the
responsibility of the manufacturer of the system or machine.
In European countries: EC Directive 89/336/EWG (EMC Directive)
In the United States: National Electrical Code (NEC) and National
Electrical Manufacturers Association (NEMA), as well as local
standards should be observed. The operator is required to adhere
to the above named standards at all times.
Installation and Operation
8
2 Installing the HACD-DPQ
Proper Use
The HACD-DPQ controller card is designed for controlling
electrohydraulic injection machines.
Applications include:
■
closed loop pressure conrol
■
closed loop position control
■
spool configuration
Proper use requires adherence to the manuals and supplementary
documentation, and observing relevant safety and operating
standards.
Personnel Selection and Qualification
Operation and Startup
Operation and startup of the HACD-DPQ controller card requires
specialized skills. Therefore this work should be performed only by
properly trained individuals.
Only persons who are trained or properly instructed should start up
and operate the HACD-DPQ controller card. Additionally the
oversight of a qualified supervisor may be advised.
Personnel are considered qualified if they are familiar with the
installation, startup and operation of the HACD-DPQ controller card,
and with all the warning notes and safety regulations contained in
the accompanying documentation.
Work on the electrical equipment must be performed only by
qualified specialists or by personnel appropriately instructed
and under the supervision and guidance of persons qualified
and familiar with electrical safety standards.
An electrical specialist is someone who, based on his technical
knowledge and training, as well as knowledge of the relevant
standards, is able to evaluate the tasks assigned to him, recognize
potential hazards and take the appropriate safety measures.
Repair and troubleshooting
Installation and Operation
Repair and troubleshooting requires specialized skills. Therefore,
this work should be performed only by trained and designated
specialists.
9
2 Installing the HACD-DPQ
Design Changes and Electrical Installation
User changes to the HACD-DPQ controller card may result in
safety hazards.
Note the following recommendations on electrical installation:
10
■
Use low-capacitance cables. Make cable connections without
intermediate connections whenever possible.
■
Control electronics should be isolated from electromagnetic
noise sources (IE: V/F drives).
■
Power wiring should not be routed in the vicinity of control
electronics.
■
Power wiring should not be routed in the vicinity of control wiring
or cables.
■
Route sensor lines separately.
■
Maintain a distance of at least 1 meter from antenna lines, RF
devices and radio equipment.
■
When using differential inputs switch both inputs on and off at
the same time.
■
When switching signal inputs, use dry circuit rated relays with
gold-plated contacts (low voltages, low currents)
■
Always shield all analog signal lines. Connect shields at the card
end only, connecting to the "Shield" terminal, and leave the
other end open to prevent ground loops.
■
Connect to an appropriate system ground using stranded copper
wire (min 2.5mm2 / 12 AWG)
The system ground is an essential component of the EMC
protection for the controller card. The ground provides a path for
noise that could otherwise enter the controller card through the
signal and power supply lines. Noise is bypassed only if the
system ground does not couple noise into the controller card.
Rexroth also recommends shielding solenoid wiring.
■
Do not use logical signals from the controller card (IE: “OK”
signal) for switching machine safety circuits
(see European Norm "Safety Requirements for Fluid Power
Systems and Components" EN982:1996).
■
If bus system is used, take care on the specific bus
specifications:
CANopen: CiA-301, CiA-302
Installation and Operation
2 Installing the HACD-DPQ
2.2 Repair and Troubleshooting
If the control cabinet contains additional electrical components
utilizing high voltage, always observe safety standards to prevent
accidents ! Use appropriate protective gear, such as safety shoes
and safety gloves, when prudent !
Use appropriate tools (IE: insulated tools)
Before opening control cabinet doors, open the main disconnect.
To ensure safe working conditions, observe the following safety
rules:
■
Remove all power
■
Ensure against unintended energization: lockout devices when
possible, and use lockout warning tags
■
Verify that voltage is not present
■
Cover or close off adjacent areas that are still energized.
If work on energized components is necessary, have a second
person present as a safety backup to actuate an E-STOP switch or
open the main disconnect, if necessary. Use insulated tools only.
Installation and Operation
11
2 Installing the HACD-DPQ
2.3 Transport, Storage and Handling the Controller Card
The packaging contains notes on handling of the controller card.
These must be strictly followed.
SDLC
ACHTUNG
Elektrostatisch gefährdete
Bauelemente.
ATTENTION
Static Sensitive
Devices
ATTENTION
Circuits sensibles à
l' électricité statique.
Handle only at
Static Safe Work
Stations
Manipulation uniquement Handhabung daher nur an
autorisée sur un poste de geschützten Arbeitsplätzen
erlaubt.
travail protégé.
HACD_HW_DE_2-1
Fig. 1 Notes for handling printed on the packaging
Observe the following:
■
Keep the controller card away from moisture and dust
■
Observe the allowable storage temperature range of –20° C to
+80 °C.
(allowable operating temperature: 0 – 50° C)
______________________________________________________________
NOTE!
Electrostatic discharge (ESD) can damage
components on the controller card. To prevent
damage, observe the following recommendations.
Discharge static voltage from your body using
accepted practices.
Work in a safe environment. Do not use any devices
in the working environment that generate or hold static
charge. Avoid working with the controller card in areas
where floors or work surfaces is composed of
materials that can generate a static charge.
Handle the controller card carefully. Do not touch any
exposed pins or electronic components.
Transport and store the control card in its original
packaging.
______________________________________________________________
12
Installation and Operation
2 Installing the HACD-DPQ
2.4
Card Installation
Remove the card from its packaging only at a protected work place.
Do not touch any electrical components when placing the controller
card in its proper card holder as shown in Fig. 2..
Correctly installing the HACD-DPQ controller card:
Remove power from the rack when installing the card.
Hold the card by the front panel and remove it from the
packaging.
Slide the card into the guide rails of the rack without using
excessive force, as shown in Fig. 2 “Installing the control card”.
Snap the edge connector in place by gently pressing on the front
panel.
card
male connector
mounting
screws
guide rails
Faceplate
HACD_HW_EN_2-2
Fig. 2 Installing the controller card
Tighten the two mounting screws on the front panel.
9 The card is now installed correctly.
Installation and Operation
13
2 Installing the HACD-DPQ
2.5
Edge Connector Terminals and Pin Assignments on the
The edge connector is a 64-pin, Type G (DIN 41612).
The pin assignments for the edge connector are not fully downward
compatible with older amplifier products.
Pin assignment tables:
Row d
14
Pin Description
Type
Specification
2
DI 1 Back Pressure
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
4
DI 2 AUTO
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
6
DI 3 Force Transfer
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
8
DI 4 Inject/Jog +
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
10
DI 5 Incremental
Home
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
12
DI 6 Post Decom/Jog Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
14
DI 7 Analog Inject
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
16
DI 8 Analog
Passthrough
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub
18
Enable
Discrete log 0 = 0..2V,
input
log 1 = 16..Ub (H active)
20
DO 1 Velocity Profile Discrete Ub, 50mA, short-circuit
act
output
protected
22
OK 2)
24
nc
26
DO 2 Signal Fault
28
nc1)
30
Valve Output 1
32
Valve Output 2 or
Analog
pressure feedback or output
position feedback
Discrete Ub, 50mA,
output
short-circuit protected
1)
Discrete Ub, 50mA,
output
short-circuit protected
Analog
output
± 10V, Rload min = 1k
0-20mA, Rload max = 500R
± 10V, 10mA Rload min =
1k
1)
= Pin not used in the basic version, but intended for later expansions. Do not
connect to these pins.
2)
= Signal indicates ready status the of the Controller card.
Installation and Operation
2 Installing the HACD-DPQ
Row b
Pin Description Type
Specification
2
Cavity
Pressure +
Analog input
Differential input:
± 10V (Rin>100kΩ),
4
Cavity
Pressure -
Analog input
0...20mA with Rin = 100Ω 3)
6
Pressure FB Analog input
#1 +
Differential input:
± 10V (Rin>100kΩ),
8
Pressure FB Analog input
#1-
0...20mA with Rin = 100Ω 3)
10
Pressure
Command +
Analog input
Differential input:
± 10V (Rin>10MΩ),
12
Pressure
Command -
Analog input
0...20mA with Rin = 100Ω 3)
14
Pressure FB Analog input
#2+
Differential input:
± 10V (Rin>100kΩ),
16
Pressure FB Analog input
#2 -
0...20mA with Rin = 100Ω 3)
18
Analog Cyl
Pos Fdbk +
Analog input
Differential input:
± 10V (Rin>100kΩ),
20
Analog Cyl
Pos Fdbk -
Analog input
0...20mA with Rin = 100Ω 3)
22
Velocity
Command +
Analog input
Differential input:
± 10V (Rin>100kΩ),
24
Velocity
Command -
Analog input
0...20mA with Rin = 100Ω 3)
26
Valve Output Analog output
3 or pressure
feedback or
position
feedback
± 10V, 10mA Rload min = 1k
28
AGND
Analog GND
0V, reference for analog
outputs
30
REF-
Reference
voltage
- 10V
- 10V, short-circuit protected,
30mA,
32
REF+
Reference
voltage
+ 10V
+ 10 V, short-circuit
protected, 30mA,
3)
Installation and Operation
= Because of the input circuitry the voltage drop over the high wattage resistor is
dependant on the input current. This voltage drop has a linear character with
has a value of 1,7 V at 4 mA and 3,5V at 20 mA.
15
2 Installing the HACD-DPQ
Row z
Pin Description Type
2
nc
4
nc1)
6
nc1)
8
nc1)
10
Shield
12
nc1)
14
nc1)
16
nc1)
18
nc1)
20
Ground
System ground
22
DO 3 Back
Pressure
Discrete output
Ub, 50mA, short-circuit
protected
24
DO 4 Inject
Forward
Discrete output
Ub, 50mA, short-circuit
protected
26
DO 5 Decom Discrete output
Achieved
Ub, 50mA, short-circuit
protected
28
DO 6 At Shot Discrete output
Size
Ub, 50mA, short-circuit
protected
30
UB
Supply voltage
UB + 24V DC
UB(t) max + 35V DC
UB(t) min + 21V DC
32
LO
Supply GND
0V
1)
16
Specification
1)
Shield
internally connected with z
20
= Pin not used in the basic version, but intended for later expansions. Do not
connect to these pins.
Installation and Operation
2 Installing the HACD-DPQ
Row f
Pin Description Type
Specification
2
DO 7 At
Pressure
Discrete output
Ub, 50mA, short-circuit
protected
4
Clk +
Clock output
SSI encoder
5V Signal RS-485
compatible
6
Clk -
Clock output
SSI encoder
5V Signal RS-485
compatible
8
Data +
Data input
SSI encoder
5-24V Signal
UA1
Incremental
encoder input
Data -
Data input
SSI encoder
/UA1
Incremental
encoder input
12
UA2
Incremental
encoder input
5-24V Signal
14
/UA2
Incremental
encoder input
5-24V Signal
16
UA0
Incremental
encoder input
5-24V Signal
18
/UA0
Incremental
encoder input
5-24V Signal
20
nc1)
22
nc1)
24
nc1)
26
nc1)
28
CAN Gnd
CAN Bus refence CAN Specification
30
CANL
CAN Bus
input / output
CAN Specification
32
CANH
CAN Bus
input / output
CAN Specification
10
1)
Installation and Operation
5-24V Signal
= Pin not used in the basic version, but intended for later expansions. Do not
connect to these pins.
17
3 Startup of the HACD-DPQ Controller Card
3 Startup of the HACD-DPQ Controller Card
3.1
Preparing for Use
The startup procedure for the HACD-DPQ controller card depends
on a variety of factors that are determined by the individual
application. For this reason, only the basic startup steps are
described in this manual.
Preparing the controller card for use:
Carefully check cabling.
Apply power to the HACD-DPQ controller card.
Fig. 3 Front panel of the HACD-DPQ Controller Card
9 The controller card performs an internal function test.
9 The display on the controller card shows the manufacturer name
and version number in scrolling text (when powered up)
Installation and Operation
18
3 Startup of the HACD-DPQ Controller Card
3.2
Installing BODAC software
BODAC software ordering code SYS-HACD-BODAC-01/ (S/N
R900777335) can be downloaded via Internet
(www.boschrexroth.com/hacd). This software is used for initial
startup and as a convenient configuration and monitoring tool for
the controller card. BODAC can be used to configure the settings
and parameters for optimal operation of the HACD-DPQ controller
card. The connected HACD-DPQ card configures the function,
menus and program windows in BODAC. This makes using the
software easy.
Installation Requirements
Hardware
Software
100% IBM compatible PC with the following minimum
requirements:
■
200 MHz Pentium processor (or equivalent)
■
32 MB working memory (RAM)
■
VGA graphics card, minimum resolution: 800x600 pixels
■
Hard drive with minimum 2 MB available space
■
CD-ROM drive
■
Mouse
■
Available serial port or USB/RS232 converter (S/N
R901066684)
■
Operating system: WindowsTM NT / 2000 / XP.
If the hardware/software requirements are met, you can install
BODAC as described in the next section.
BODAC Setup
To start the installation of BODAC, execute the “Setup.exe“ file.
Installation and Operation
19
3 Startup of the HACD-DPQ Controller Card
Installing BODAC software:
Insert the CD-ROM and locate the file “Setup.exe“.
Double-click on “Setup.exe“.
9 The setup program will load and display a start screen.
To run Setup, follow the instructions on the screen.
9 BODAC software will then be installed.
3.3
Initial startup with BODAC
After installing the HACD-DPQ controller card in a rack, as
described in section 2.4, "Installing the card", and all initial steps
have been completed properly, the card startup is ready.
Before proceeding with the following steps, be sure that the
following requirements have been met:
■
Serial interface cable is available
■
A serial port on the PC is available
■
BODAC software is installed.
Proceed with the initial startup:
■
Connect serial cable (S/N R9000776897) to the connector on
the HACD-DPQ card.
Plug serial cable into the serial port (COM) on the PC (or use
USB converter – S/N R901066684).
9 The HACD-DPQ card and PC are now connected.
Start the BODAC software.
Perform the software-side startup as described in the “Start-up
and Operation” document.
20
Installation and Operation
3 Startup of the HACD-DPQ Controller Card
Notes
Installation and Operation
21
4 HACD-DPQ Operation
4 HACD-DPQ Operation
4.1
Display/Input Keys and Connectors on the Front Panel
You can use the display, input keys and connectors on the front
panel of the HACD-DPQ to check parameters and settings, attach
diagnostic instruments and connect the card to a PC.
The following illustration shows an overview of the display, input
keys and connectors on the front panel.
Fig. 4 Display, input keys and connectors on the control card
Display
The display is four characters in length. Messages that exceed four
characters are displayed as a scrolling display.
When parameters are displayed, the negative or positive sign is
indicated by the “+” and “-“ LEDs.
LEDs for Discrete I/O
Serial port
The input LEDs indicate the state of the discrete input signals. The
output LEDs show the state of discrete outputs from the controller
card. When a signal is present on a discrete I/O, the associated
LED will illuminate.
The serial port on the front panel is configured as a standard RS232 port using a 9-pin D-Sub female connector. A standard 9 pin
serial data cable is used to connect the serial port to a PC.
Buttons
Installation and Operation
22
4 HACD-DPQ Operation
Four buttons are located on the front panel of the card. The
functions of these buttons are described in detail in section 4.4
,"Performing operations”.
4.2
Diagnostics Test Jacks
The diagnostic test jacks on the front panel of the card can be used
to connect external test instruments. Two analog voltage signals
are available to perform measurements.
4.3
Menu Tree for Setup and Parameters
The following contains an overview of the menus that can be
selected using the buttons on the HACD-DPQ controller card.
Shown are the parameters and settings that are available.
An overview of the items listed below are shown on the following
pages:
■
Menu tree "Parameters Part 1"
■
Menu tree "Parameters Part 2"
■
Menu tree "Parameters Part 2"
■
Menu tree "Parameters Part 2"
■
Menu tree "Setup"
For a detailed description of the settings and parameters, please
refer to document: “Starting up the HACD-DPQ Control Card and
Operation of BODAC Software”.
Installation and Operation
23
4 HACD-DPQ Operation
Ebene 1
Ebene 2
Ebene 3
Ebene 4
Ebene 5
INJECTION PROFILE
with "ENTER“
INJECTION
back to menu
Veloc. 1 mm/sec
xxxx.x [0~5000.0]
P max Limit 1 bar
xxxx.x [0~5000.0]
Position 2 mm
xxxx.xx [-100~5000.00]
Veloc. 2 mm/sec
xxxx.x [0~5000.0]
P max Limit 2 bar
xxxx.x [0~5000.0]
Position 3 mm
xxxx.xx [-100~5000.00]
Veloc. 3 mm/sec
xxxx.x [0~5000.0]
P max Limit 3 bar
xxxx.x [0~5000.0]
Position 4 mm
xxxx.xx [-100~5000.00]
Veloc. 4 mm/sec
xxxx.x [0~5000.0]
P max Limit 4 bar
xxxx.x [0~5000.0]
Position 5 mm
xxxx.xx [-100~5000.00]
Veloc. 5 mm/sec
xxxx.x [0~5000.0]
P max Limit 5 bar
xxxx.x [0~5000.0]
Position 6 mm
xxxx.xx [-100~5000.00]
Veloc. 6 mm/sec
xxxx.x [0~5000.0]
P max Limit 6 bar
xxxx.x [0~5000.0]
Position 7 mm
xxxx.xx [-100~5000.00]
Veloc. 7 mm/sec
xxxx.x [0~5000.0]
Main Menu
(continued)
P max Limit 7 bar
xxxx.x [0~5000.0]
Fig. 5 Menu tree "Parameters Part 1"
24
Installation and Operation
4 HACD-DPQ Operation
Ebene 1
Ebene 2
Ebene 3
Ebene 4
Ebene 5
Main Menu
(continued)
Position 8 mm
xxxx.xx [-100~5000.00]
Veloc. 8 mm/sec
xxxx.x [0~5000.0]
P max Limit 8 bar
xxxx.x [0~5000.0]
Position 9 mm
xxxx.xx [-100~5000.00]
Veloc. 9 mm/sec
xxxx.x [0~5000.0]
P max Limit 9 bar
xxxx.x [0~5000.0]
Position 10 mm
xxxx.xx [-100~5000.00]
Veloc. 10 mm/sec
xxxx.x [0~5000.0]
P max Limit 10 bar
xxxx.x [0~5000.0]
TRANSFER
Position mm
xxxx.x [0~5000.0]
Hydraulic Press. bar
xxxx.x [0~5000.0]
Hydraulic Pos. mm
xxxx.x [0~5000.0]
Mold pressure bar
xxxx.x [0~5000.0]
HOLDING
Pressure 1 bar
xxxx.x [0~5000.0]
Time 1 sec
xxx.xx [0~999.99]
Veloc Limit 1 %
xxx.xx [+/-100.00]
Pressure 2 bar
xxxx.x [0~5000.0]
Time 2 sec
xxx.xx [0~999.99]
Main Menu
(continued)
Veloc. Limit 2 %
xxx.xx [+/-100.00]
Fig. 6 Menu tree "Parameters Part 2"
Installation and Operation
25
4 HACD-DPQ Operation
Ebene 1
Ebene 2
Ebene 3
Ebene 4
Ebene 5
Main Menu
(continued)
Pressure 3 bar
xxxx.x [0~5000.0]
Time 3 sec
xxx.xx [0~999.99]
Veloc. Limit 3 %
xxx.xx [+/-100.00]
Pressure 4 bar
xxxx.x [0~5000.0]
Time 4 sec
xxx.xx [0~999.99]
Veloc. Limit 4 %
xxx.xx [+/-100.00]
Pressure 5 bar
xxxx.x [0~5000.0]
Time 5 sec
xxx.xx [0~999.99]
Veloc. Limit 5 %
xxx.xx [+/-100.00]
BACK PRESSURE
Pressure 2 bar
xxxx.x [0~5000.0]
Screw Speed 2 %
xxx.xx [+/-100.00]
Position 3 mm
xxxx.x [0~5000.0
Pressure 3 bar
xxxx.x [0~5000.0]
Screw Speed 3 %
xxx.xx [+/-100.00]
Position 4 %
xxxx.x [0~5000.0
Pressure 4 bar
xxxx.x [0~5000.0]
Screw Speed 4 %
xxx.xx [+/-100.00]
Shot Size mm
Main Menu
xxxx.x [0~5000.0
(continued)
Fig. 7 Menu tree "Parameters Part 3"
26
Installation and Operation
4 HACD-DPQ Operation
Ebene 1
Ebene 2
Ebene 3
Ebene 4
Ebene 5
Main Menu
(continued)
DECOMPRESSION
Pre-Decomp Pos 1 mm
xxxx.x [0~5000.0]
Pre-Decomp Veloc. 1 %
xxx.xx [+/- 100.00]
Post-Decomp Pos 5 mm
xxxx.x [0~5000.0]
Post-Decomp. Veloc 5 %
xxx.xx [+/- 100.00]
Fig. 8 Menu tree "Parameters Part 4"
Ebene 1
Ebene 2
Ebene 3
Ebene 4
Ebene 5
Setup
with „ENTER + ESC“
Sprache / Language
to configuration
English
menu
Deutsch
Password
Off
On
xxxx [1~9/A~Z]
Fig. 9 Menu tree "Setup"
Installation and Operation
27
4 HACD-DPQ Operation
4.4
Display/Input Key Operations
All operations can be performed directly on the card using the
"UP", "DOWN", "ENTER" and "ESCAPE" keys.
The keys are especially useful for quickly and easily
checking, changing or correcting parameters and settings.
Always use BODAC software for the initial startup before
placing the card in service.
Before making any changes to parameters or settings, familiarize
yourself with the menu structure of the card. This can be found in
section 4.3:"Menu tree for settings and parameters".
Key functions:
z
UP
Pressing the "UP" key moves in the upward direction, within the
selected level, to available menu items. (for an overview, see
section 4.3: "Menu tree for settings and parameters")
z
DOWN
Pressing the "DOWN" key moves in the downward direction, within
the selected level, to available menu items (for an overview, see
section 4.3: "Menu tree for settings and parameters").
z
ENTER
Change menu mode:
Press the "ENTER" key for 2 seconds or longer, to switch to
configuration mode – "EDIT Parameters".
Change menu level:
Press the “ENTER“ key to take you one level lower in the
menu structure, or confirms an entered value.
Note: The entered value is stored immediately in memory!
z
ESCAPE
z
ENTER
+
z
ESCAPE
Pressing the "ESCAPE" key takes you one level higher in the menu
structure.
Pressing the “ENTER“ and “ESCAPE“ keys simultaneously opens
the configuration menu.
The configuration menu is structured in levels. The first level
contains main categories, below which are additional subcategories and settings. Depending on the entry selected, a main
category may have up to 4 sub-levels.
The following figure illustrates the menu level structure.
28
Installation and Operation
4 HACD-DPQ Operation
Fig. 10 Example of the menu levels in configuration mode
Changing from Run Mode to Configuration Mode – "EDIT
Parameters":
The card must be in run mode.
The display will show scrolling text to display the manufacturer’s
name, the software version for the controller, or a custom
configured text string.
Press and hold “Enter“ for at least 2 seconds until the display
reads “INJECT PROFILE“.
9 The controller card is now in "EDIT Parameter" mode.
Changing from Run Mode to Configuration Mode:
The card must be in run mode.
The display will show scrolling text to display the manufacturer’s
name, the software version for the controller, or a custom
configured text string.
Press and hold "Enter" and "ESCAPE" simultaneously for at
least 2 seconds (except when in "EDIT Parameter“ mode, see
above) until the display reads “Setup“.
9 The controller card is now in configuration mode.
To exit Configuration Mode:
As an example, the second level of the “Setup” menu is shown.
The display on the controller card shows the option
“Sprache/Language“.
Press “ESCAPE”.
9 The display is scrolling “Setup“.
Installation and Operation
29
4 HACD-DPQ Operation
Press “ESCAPE”.
9 The display will show scrolling text to display the manufacturer’s
name, the software version for the controller, or a custom
configured text string
9 .
If while in Configuration Mode no entry is made within one
minute, the controller card will automatically return to
successively higher menu levels until Run Mode is
reached.
The HACD-DPQ Control Card is fully operational in
Configuration Mode.
To change a parameter using the input keys:
As an example, the parameter "TRANSFER BY Hydraulic Pos mm"
is shown. In this case, set the parameter to: “10“. The card is now
in Run Mode.
The display will show scrolling text to display the manufacturer’s
name, the software version for the controller, or a custom
configured text string.
______________________________________________________________
WARNING!
When changing parameters using the input keys,
hardware inputs are configured even when the
discrete input “Enable” is active.
caution:
Do not change any analog input from voltage to
current or current to voltage when active.
Changing the analog inputs configuration may result in
incorrectly interpreted values.
This can result in uncontrolled system operation
and damage to the machine!
______________________________________________________________
Press and hold the “Enter“ key until the display reads “INJECT
PROFILE“.
9 The card is now in Configuration Mode.
Press the “ENTER” key to select “INJECT PROFILE”.
9 The card is now at the second level of the Configuration Menu,
“INJECT PROFILE“ mode.
Press the “UP” or “DOWN” keys to select “TRANSFER BY”.
Press “ENTER”.
30
Installation and Operation
4 HACD-DPQ Operation
9 The menu entry “Hydraulic Pos. mm” is shown.
Press “ENTER”.
Press the “UP” or “DOWN” keys to select “Hydraulic Pos mm”.
Press “ENTER”.
9 The current value is shown.
Press “UP”.
This creates a positive sign. Pressing „DOWN“ gives the value a
negative sign.
Press “UP” until "1" is displayed.
Press “ENTER”.
Press “UP” until "0" is displayed.
Press “ENTER”.
Press “UP” until "." is displayed.
Press “ENTER”.
Press “UP” until "0" is displayed.
Press “ENTER”.
Press “UP” until "0" is displayed.
Press “ENTER”.
9 The parameter “TRANSFER BY Hydraulic Pos mm“ 10 mm is
now entered and displayed.
Exit the Configuration Menu by pressing “ENTER" five times.
Installation and Operation
31
4 HACD-DPQ Operation
Notes
32
Installation and Operation
5 Diagnostics
5
Diagnostics
5.1 Diagnostic Options on the HACD-DPQ Controller Card
Diagnostics terminal
The diagnostic test jacks on the front panel of the HACD-DPQ
controller card (see section 4.1 Display/Input Keys and Connectors
on the , Fig. 4 ) provide two analog outputs with the following
ratings:
■
X1, 10 Volts for test equipment having Ri 〈 100 kΩ
■
X2, 10 Volts for test equipment having Ri 〈 100 kΩ
■
COM, ground
Test Jack "X1"
On test jack “X1“ there are severall signals available from where
you can choose. The signal is selected in BODAC.
Test Jack "X2"
Using the Testjack menu in BODAC, the signal to be measured can
be selected.
Display
indication when an error
occurs
During initial startup, BODAC software can be used to select the
action of the controller when an error occurs (available in the
“Error“ screen). If the controller card detects an error, which has
been configured with BODAC software, the error will be displayed
on the HACD-DPQ controller card.
If the control card detects an error configured with BODAC
software, respond as follows:
The display will flash "ERR" (Error) on the controller
card!
Press “ENTER” to display the error message and
clear the error.
The procedure for selecting the action desired when an error
occurs can be found in the document “Starting up the HACD-DPQ
Control Card and Operation of the BODAC Software".
5.2 Diagnostics Using BODAC
The BODAC software includes additional detailed diagnostics
capabilities.
Installation and Operation
33
4 HACD-DPQ Operation
The “Motion Data” screen and the “Status” screen display the
current status of the controller card and of the connected sensors
and devices.
Motion Data Screen
Status Screen
The Motion Data screen displays the internal control signal values
in the controller card. This provides a quick overview of the process
status and values.
The Status screen is used to display the status of the controller
card. Each entry will display either “OK”, “WARNING” or “ERROR"
as a value.
For additional information on the Motion Data screen and the
Status screen, refer to document " Starting up the HACD-DPQ
Control Card and Operation of the BODAC Software ".
34
Installation and Operation
6 Detecting Errors
6
Detecting Errors
6.1 Error Messages
Error message
Description
+/- 10V voltage
Reference voltage +10V (b32) or reference voltage –10V
(b30) outside allowable tolerances.
24 V Power
Supply voltage Ub (z30) outside allowable tolerances
21...35V.
DO1~DO7 and
ENABLE short circuit
Short circuit on one or more of the 8 discrete outputs.
Checksum Flash
Checksum error in program or data memory (Flash or
EEprom)
Memory error
Error in working memory (RAM)
Analog Input AI1
Pressure Command
The signal on analog input AI1 is outside the valid signal
range (adjustable in Analog Config Screen in BODAC).
Analog Input AI2
Pressure FB #1
The signal on analog input AI2 is outside the valid signal
range (adjustable in Analog Config Screen in BODAC).
Analog Input AI3
Cavity Pressure
The signal on analog input AI3 is outside the valid signal
range (adjustable in Analog Config Screen in BODAC).
Analog Input AI4
Pressure FB #2
The signal on analog input AI4 is outside the valid signal
range (adjustable in Analog Config Screen in BODAC).
Analog Input AI5
Analog Cyl Pos Fdbk
The signal on analog input AI5 is outside the valid signal
range (adjustable in Analog Config Screen in BODAC).
Analog Input AI6
Velocity Command
The signal on analog input AI6 is outside the valid signal
range (adjustable in Analog Config Screen in BODAC).
SSI
Cable fault on SSI encoder
Max. Freq. Fault
Max. frequency for the incremental encoder is exceeded
Encoder Channel A
Cable fault on the Incremental encoder
Encoder Channel B
Cable fault on the Incremental encoder
Bus Fault
Profibus: The slave has left condition “DATA_EXCHANGE”
CANopen: The node has left the condition
“OPERATIONAL”
DeviceNet: The node has left the condition “ONLINE”
6.2 Changing fuses
The controller card is protected against overload by means of a
fuse. The fuse is the following type:
■
Installation and Operation
F / 4A / 250V
35
6 Detecting Errors
______________________________________________________________
NOTE!
The fuse is defective and must be replaced!
The fuse has opened due to mechanical damage or a
product defect.
In this case, replace the fuse with a new one of the
type indicated above.
The fuse has opened due to external connections, IE:
externally connected components or wiring connected
to the controller card have faulted.
In such cases, diagnose and correct the problem that
caused the fuse to open.
Only then replace the fuse with a new one.
______________________________________________________________
Replacing the fuse on the HACD-DPQ Control Card:
Remove HACD-DPQ controller card the card holder (reverse of
the procedure described in section 2.4 Card Installation )
Gently remove the fuse from the fuse holder (see Fig. 11 ).
HACD_HW_EN_6-2
Fig. 11 Fuse on the HACD-DPQ Controller Card
36
Installation and Operation
6 Detecting Errors
Use a suitable test device to check the fuse. (continuity test)
If the fuse is defective, replace it with the same type.
Reinstall the HACD-DPQ controller card and perform a
functional test.
Installation and Operation
37
6 Detecting Errors
Notes
38
Installation and Operation
7 Index
7
Index
Action symbol ..................................................5
Analog GND...................................................15
Analog input...................................................15
BODAC setup routine ....................................19
BODAC software ...........................................19
Characters .......................................................5
compatible .....................................................14
Configuration mode .......................................29
Control card
Installation ...........................................................13
Control parameter
|CMD-LFB|< ........................................................25
|CMD-LFB|> ........................................................25
D 25
D (LFB1)..............................................................25
I 25
P 25
T1 25
Diagnostics terminal ................................23, 33
Diagnostics using BODAC.............................33
Differential inputs ...........................................10
Display ...........................................................22
DOWN ...........................................................28
Drives
Electromechanical and electrohydraulic ...............5
EC Directive 89/392/EWG (Machine Directive)8
Edge connector..............................................14
EMC Regulations.............................................8
ENTER...........................................................28
Error conditions..............................................33
Error messages .............................................35
ESCAPE ........................................................28
Front panel.....................................................13
Fuse...............................................................35
HACD.............................................................33
Initial startup ..................................................33
Installation......................................................10
Installation requirements................................19
Keys...............................................................28
LED´s for digital in-/.outputs ..........................22
Link/Controller..........................................26, 27
Menu tree
Overlap..........................................................26, 27
Residual speed..............................................26, 27
Parameter changing ...................................... 30
Password....................................................... 27
Power cables................................................. 10
Reference voltage ......................................... 15
Result symbol.................................................. 5
Run mode...................................................... 29
Running text ............................................ 29, 30
Safety fuse .................................................... 35
Safety requirements ........................................ 4
Sensor lines................................................... 10
Serial port ...................................................... 22
Setpoint parameter
Acceleration.........................................................25
Delay ...................................................................25
Setpoint ...............................................................25
Speed-.................................................................25
Speed+ ................................................................25
Shield ............................................................ 10
Shielding........................................................ 10
Sprache/Language ........................................ 27
Supply GND .................................................. 16
Supply voltage............................................... 16
Symbols........................................................... 5
System ground .............................................. 10
Transport ....................................................... 12
Troubleshooting............................................. 11
UP 28
Warning symbol
Equipment damage ...............................................6
Hazard potential, electrical current........................5
Hazard potential, general ......................................5
Parameters Part 1 ...............................................25
Parameters Part 2 ...............................................26
Parameters Part 3 ...............................................26
Parameters Part 4 ...............................................27
Setup ...................................................................27
Noise sources ................................................10
Output compensation
Installation and Operation
39
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
[email protected]
www.boschrexroth.com
© This document, as well as the
data, specifications and other
information set forth in it, are the exclusive property of Bosch Rexroth
AG. It may not be reproduced or
given to third parties without its
consent.
The data specified above only
serve to describe the product. No
statements concerning a certain
condition or suitability for a certain
application can be derived from
our information. The information given does not release the user from
the obligation of own judgment and
verification. It must be remembered
that our products are subject to a
natural process of wear and aging.
Printed in Germany
RE 30146-B/08.07
Replaces: 11.06
Digital drive controller
for hydraulic axes with
sercos interface
Type VT-HNC100...3X/S...
Operating instructions
RE 30159-B/10.11
Replaces: 10.09
English
The data specified above only serve to describe the product. No statements concerning
a certain condition or suitability for a certain
application can be derived from our information. The information given does not release
the user from the obligation of own judgment
and verification. It must be remembered that
our products are subject to a natural process of
wear and aging.
© This document, as well as the data, specifications and other information set forth in it, are
the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties
without its consent.
The cover page shows a sample configuration.
Thus, the delivered product may differ from the
picture shown.
The original operating instructions were prepared in German.
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
3/24
Inhalt
1 About this document.......................................................................................4
1.1 Issue status / version of the documentation..............................................4
1.2 Related documents....................................................................................4
2 General safety instructions............................................................................5
2.1 Intended use..............................................................................................5
2.2 Improper use..............................................................................................5
2.3 Personnel qualification...............................................................................6
2.4 Safety instructions in this document..........................................................6
2.5 Adhere to the following instructions...........................................................7
3 Delivery contents...........................................................................................10
4 Product description.......................................................................................11
4.1 Pin assignments......................................................................................11
5Assembly........................................................................................................15
5.1Unpacking................................................................................................15
5.2 Installation conditions..............................................................................15
5.3 Recommended accessories....................................................................15
5.4 Assembling the VT-HNC100...3X/S.........................................................16
6Maintenance...................................................................................................18
6.1 Cleaning and care....................................................................................18
6.2Repair......................................................................................................18
7 Disassembly and replacement.....................................................................19
7.1 Required tools..........................................................................................19
7.2 Preparing disassembly............................................................................19
7.3 Disassembling the VT-HNC100...3X/S....................................................19
7.4 Preparing storage and further use...........................................................20
8Disposal..........................................................................................................20
8.1 Environmental protection.........................................................................20
9Troubleshooting.............................................................................................21
9.1 How to proceed for troubleshooting.........................................................21
10Appendix.........................................................................................................22
10.1Address directory.....................................................................................22
4/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
About these instructions
1 About this document
These instructions contain important information on the safe and appropriate
assembly, transport, commissioning, operation, maintenance, disassembly and
simple troubleshooting of the VT-HNC100...3X/S digital axis control.
Read these instructions completely, especially chapter 2 “General safety instructions” before working with the VT-HNC100...3X/S... digital axis control.
1.1Issue status / version of the documentation
Table 1: Issue status / version of the documentation
Document
Issue date
Replaces
Change
RE 30159-B
10.11
10.09
--
1.2Related documents
The VT-HNC100...3X/S... digital axis control is a system component.
Also observe the following instructions:
•
•
•
•
•
Product information RE 09956
Technical data sheet RE 30159
Declaration of environmental compatibility RE 30139-U
Functional description RE 30159-FK
Parameter description RE 30159-PA
Also observe the generally applicable, legal or otherwise binding regulations of
the European or national legislation and the rules for the prevention of accidents
and for environmental protection applicable in your country.
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
5/24
General safety instructions
2 General safety instructions
The VT-HNC100...3X/S... digital axis control has been manufactured according
to the accepted rules of current technology. There is, however, still the risk of
personal injury or damage to equipment if the following general safety instructions
and the warnings before the steps contained in these instructions are not complied with.
ff Read these instructions completely and thoroughly before working with the
VT-HNC100...3X/S....
ff Keep these instructions in a location where they are accessible to all users at
all times.
ff Always include the operating instructions when you pass the
VT-HNC100...3X/S... on to third parties.
ff Only operate the VT-HNC100...3X/S... in a technically unobjectionable condition and as intended, in a safety- and risk-conscious way, considering these
instructions.
ff In case of failures impairing the safety and changes in the operating behavior,
immediately stop the VT-HNC100...3X/S... and inform the responsible personnel about the failures.
2.1Intended use
The VT-HNC100...3X/S... is exclusively intended for being integrated in a machine or system or for being assembled with other components to form a machine
or system. The product may be commissioned only if it has been integrated in the
machine/system for which it is designed. Observe the operating conditions and
performance limits specified in the technical data.
The VT-HNC100...3X/S... is used for the open and closed-loop control of position,
pressure and velocity of electro-hydraulic axes. When using the unit, you moreover need superordinate control logics with corresponding I/O components that in
connection with the VT-HNC100...3X/S... are responsible for the holistic control of
the machine's motion sequence and also its monitoring as regards safety.
The VT-HNC100...3X/S... must not be used in explosive environments.
The VT-HNC100...3X/S... is a work appliance and not designed for private use.
Intended use includes having read and understood these instructions, especially
the chapter 2 “General safety instructions”.
2.2Improper use
Any use of the VT-HNC100...3X/S... other than described in chapter 2.1 “Intended
use” is considered as improper.
6/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
General safety instructions
2.3Personnel qualification
Assembly, commissioning and operation, disassembly, service (including maintenance and repair) require basic mechanical, hydraulic, electrical and control
knowledge as well as knowledge of the appropriate technical terms. In order to
ensure operating safety, these activities may therefore only be carried out by
qualified technical personnel or an instructed person under the direction and
supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge,
and experience, as well as their understanding of the relevant conditions pertaining to the work to be done. Qualified personnel must observe the rules relevant to
the subject area.
2.4Safety instructions in this document
In these instructions, there are safety instructions before steps whenever there is
a risk of personal injury or damage to the equipment. The measures described to
avoid these hazards must be observed.
Warnings are structured as follows:
Signal word!
Type of risk
Consequences
ff Precautions
•
•
•
•
•
Warning sign (warning triangle): Draws attention to the hazard
Signal word: Identifies the degree of hazard
Type of hazard: Identifies the type or source of the hazard
Consequences: Describes the consequences in case of non-compliance
Precautions: States how the hazard can be avoided
The signal words have the following meaning:
Signal word /
warning sign
Application
DANGER!
Indicates an imminently hazardous situation which, if not avoided, will
certainly result in death or serious injury.
WARNING!
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION!
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury or damage to equipment.
If this information or further notes and additional information is disregarded, the operating procedure may be impaired.
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
7/24
General safety instructions
2.5Adhere to the following instructions
General instructions
• Observe the regulations for accident prevention and environmental protection
applicable in the country where the product is used and at the workplace.
• Exclusively use Rexroth products in a technically unobjectionable condition.
ff Check the product for visible defects, for example loose seat of screws, loose
seat of the connector plugs and connection lines, mechanical damage, etc.
• You must generally not modify or retrofit the product.
• Only use the product within the performance range provided in the technical data.
• Persons who assemble, operate, disassemble or maintain Rexroth products
must not consume any alcohol, drugs or pharmaceuticals that may affect their
ability to respond.
• Make sure that all safety equipment belonging to the product is present, has
been installed properly and is fully functional. You must not displace, bypass or
disable the safety equipment.
• If it should be necessary to disable any safety equipment temporarily, for
example for commissioning or maintenance work, always take the appropriate
measures to ensure that no hazard to a person's life or health or to property
may occur. Also observe the superordinate operating instructions of the machine or system.
• The warranty only applies to the delivered configuration.
• The warranty will not apply if the product is incorrectly assembled, not used as
intended and/or handled improperly.
• Do not expose the product to any inadmissible mechanical loads under any
circumstances. Never use the product as a handle or step. Do not place any
objects on it.
8/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
General safety instructions
During assembly
• Make sure the relevant system component is depressurized and de-energized
before assembling the product or when connecting and disconnecting plugs.
Protect the system component against being switched on.
• The VT-HNC100...3X/S... should not be installed next to power electronics (e.g.
frequency converters). The power pack of the VT-HNC100...3X/S... should be
installed as close to the VT-HNC100...3X/S... as possible.
• Keep connections for the voltage supply as short as possible. Pass supply and
return lines (+24 V/GND) together. Voltage 18-30V.
Residual ripple < 1.5 Vpp, I = 1 A - 4 A (depending on the VT-HNC100...3X/S...
version and the co-supplied components).
Ensure the largest spatial separation of signal and load lines possible and do
not pass them parallely. Do not lead signal lines through strong magnetic fields.
If possible, pass signal lines without interruption. If intermediate terminals are
necessary, use a terminal block with shield bus and an assembled
VT-HNC100...3X/S... cable (max. length 2 m).
Exception VT-HNC100-C-3X/S...: Here, intermediate clamping using a corresponding terminal block/shield bus is necessary for EMC-compliance.
Load lines of two individual wires (e.g. voltage supply) are to be passed in a
parallel or drilled form.
• For signal lines, only cables with a copper braid screen should be used. The
cable screen is extensively connected with the metallized connector housing
and usually only on the VT-HNC100...3X/S... side. This is achieved by pushing
the screen back and clamping under the pull relief.
Cables should only have the actually required number of wires. If this is not
possible, the remaining wires should be laid to GND on both sides.
• Voltage supply of external components:
A digital position transducer with 24 V or 5 V supply can be additionally supplied
via the encoder interface. When supplying a 24 V encoder, the input voltage of
the VT-HNC100...3X/S... at X1S must comply with the encoder's requirements
(e.g. 24 V +/– 5%, residual ripple < 500 mV).
Analog components like pressure cells can be supplied via the socket X2A,
X2A1. The input voltage of the VT-HNC100...3X/S... must comply with the
requirements of the pressure cell.
For more information on currents etc. please refer to the technical data sheet
RE 30159.
• By snapping the housing of the VT-HNC100...3X/S... on a conductive assembly
rail, the earth connection to the control cabinet back wall is established. This
constitutes the HF earthing of the VT-HNC100...3X/S....
• Lay the cables and lines so that they cannot be damaged and no one can trip
over them.
• Before commissioning, make sure that all the seals and plugs of the plug-in
connections are installed correctly and intact to ensure that they are leakproof
and fluids and foreign bodies are prevented from penetrating the product.
• The environment must be free from electrically conductive contamination (acids,
bases, corrosive agents, salts, metal vapors, etc.) and must not be exposed
these substances.
• No silicone-containing sealing, adhesive or insulating agents must be used.
• Ensure a maintenance-friendly installation, i.e. simple access to the connection
lines. Free access to the connection side must be guaranteed.
• Before installation note down the information on the nameplates.
If after the installation, nameplates are not visible or readable any more, this
data will be quickly available to you at any time.
• Do not use electrical signals led out of the VT-HNC100...3X/S... (e.g. the Ready
for Operation signal) for switching safety-relevant machine functions! (in this
connection also see the European Standard “Safety requirements for fluid
power systems and their components - Hydraulics” EN 982:1996).
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
9/24
General safety instructions
• Troubleshoot system components as follows:
–– Switched inductivities DC: Antiparallel free-wheeling diode over actuator winding.
–– Switched inductivities AC: Type-related R/C combination over actuator winding.
–– Electric motors: R/C combination from each motor winding to earth.
–– Frequency converter: Input filter in the voltage supply of the FU.
Motor control lines shielded and laid separately from other lines and/or output
filter for motor lines.
Extensive contact of the FU housing with the control cabinet back wall.
During commissioning
• Let the product acclimate itself for several hours before commissioning, as
otherwise water may condense in the housing.
• Make sure that all electrical connections are either used or covered. Commission the product only if it is installed completely.
During operation
• Only authorized staff is allowed to operate the setting mechanisms of the
components or parts, under the proviso that the hydraulic system is used as
intended.
• Only persons who have been authorized by the operator may be granted access
to the direct operating sector. This also applies during any standstill of the system.
• In case of emergency, failure or in case of other irregularities switch off the
system and secure it against re-start.
Disposal
• Dispose of the product in accordance with the national regulations in your country.
10/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Delivery contents
3 Delivery contents
The delivery contents include:
• VT-HNC100...3X/S...
• Mating connector for X1S (type Phoenix Mini Combicon 3-pole)
• Mating connector for X2D (type Phoenix Micro Combicon 8-pole) or
X2D1 (Phoenix Mini Combicon 12-pole)
• Mating connector X2A (type Phoenix Micro Combicon 8-pole) or
X2A1 (HD-SUB 15-pole)
• Mating connector X8M (type Phoenix Micro Combicon 8-pole) or
X8M1 (HD-SUB 15-pole)
An interface cable RS232 (length 3 m; material no. R900776897) as well as an
USB RS232 converter (material no. R901066684) are not included in the delivery
contents can, however, be ordered separately.
Software is not included in the delivery contents.
Download in the Internet for commissioning software: www.boschexroth.com/hnc100
Check the delivery contents for completeness, for possible transport damage,
for suitable and complete operating instructions. Enquire about incomplete
operating instructions.
Bosch Rexroth AG
RE 30159-B/10.11 | VT-HNC100...3X/S...
11/24
Product description
4 Product description
4.1Pin assignments
VT-HNC100-C-3X/S-S-00/000, Material number R901112919
(Compact with sercos II)
X2D DIO (Digital)
Pin
8
Shield
7
OUT2
6
OUT1
5
IN 4
4
IN 3
3
IN 2
2
IN 1
1
DGND


Encoder
SSI
EnDat 2.2
Shield
Shield
24 Venc
+5 V
– Clk
– Clk
+ Clk
+ Clk
– Data
– Data
+ Data
+ Data
EGND


X8M
Pin
8
7
6
5
4
3
2
1
X3CRS232
Pin
1
2
TxD
3
RxD
4
reserved
5
GND
6
reserved
7
reserved
8
reserved
9
X1SPower
Pin
1
GND
2
GND
3
18 – 30 V



X2A AIO (Analog)
Pin
8
Shield
7
24 Vsens
6
Vout1 +
5
Vout2 +
4
Vin 1
3
Cin2 +
2
Cin1 +
1
AGND
X7
S1
S2
sercos II
TX
RX

The pins marked with “reserved” are reserved and must not be connected!
12/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Product description
VT-HNC100-1-3X/S-I-30/000, Material number R901234133
(1-axis version with sercos III and with interface optionally for incremental, EnDat 2.2 or SSI position transducer)
VT-HNC100-1-3X/S-C-30/000, Material number R901281693
(1-axis version with sercos III and with interface for 1 Vss position transducer)
Encoder
Slot 1
X8M1
Incremental
1 Vpp
– B (Inc)
– B (Inc)
+ R (Inc)
– R (Inc)
+ A (Inc)
– A (Inc)
+ R (Inc)
– R (Inc)
+ A (Inc)
– A (Inc)
+ B (Inc)
+ B (Inc)
EGND
EGND
+5 Venc
+5 Venc
EnDat 2.2
SSI
+ CLK
+ CLK
– CLK
– CLK
– Data
EGND
+ Data
+5 Venc
– Data
EGND
+ Data
+24
Venc
15
X1SPower
Pin
1
GND
2
GND
3
18 – 30 V
Slot 1 X2D1
+10 Vref
Vimp1

­
­
X7E1, X7E2
sercos III
connection
EGND

Analog
X3CRS232
Pin
1
2
TxD
3
RxD
4
reserved
5
GND
6
reserved
7
reserved
8
reserved
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Pin

– The pins marked with “reserved” are reserved and must not be connected!
– PROFIBUS DP or CANopen (connection X7P/C) are not available with the sercos version.
Pin
1
2
3
4
5
6
7
8
9
10
11
12
DIO
(Digital)
I/O 1
I/O 2
I/O 3
I/O 4
I/O 5
I/O 6
I/O 7
I/O 8
I/O 9
I/O 10
I/O 11
DGND
Slot 1 X2A1 AIO
(Analog)
Pin
1
Vin1 +
2
Vin1 –
3
Vin2 +
4
Vin2 –
5
Cin1 +
6
Cin1 –
7
Cin2 +
8
Cin2 –
9
reserved
10
AGND
11
Vout1 +
12
Vout2 +
13
Cout1
14
+24 Vsens
15
reserved
Bosch Rexroth AG
RE 30159-B/10.11 | VT-HNC100...3X/S...
13/24
Product description
Unit dimensions VT-HNC100-C-3X/S-S-00/000 (dimensions in mm)
Assembly on top hat rail TH 35-7.5 or TH 35-15 according to EN 60715





Unit dimensions VT-HNC100-1-3X/S-...-30/000 (dimensions in mm)
Assembly on top hat rail TH 35-7.5 or TH 35-15 according to EN 60715


­€
 „
ƒ
ƒ


„
‚
14/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Product description
Description of the LEDs
At the front side of the VT-HNC100...3X/S... unit, there are the following
3 LED displays:
• 3.3 V: Voltage supply of the VT-HNC100...3X/S... is OK.
• RUN: VT-HNC100...3X/S... has been initialized and is in “RUN”. The LED
flashes if the VT-HNC100...3X/S... has not been initialized.
• BUS: Field bus communication is OK.
• L:
LINK active, indicates the physical connection to the communication partner.
• S:
Status LED, the CI system is sending or receiving Ethernet telegrams.
• MS: Module status / host-dependent
• NS: Network status
Bosch Rexroth AG
RE 30159-B/10.11 | VT-HNC100...3X/S...
15/24
Assembly
5Assembly
5.1Unpacking
Dispose of the packing in accordance with the national regulations in your country.
5.2Installation conditions
For installing the product always observe the ambient conditions specified in
RE 30159.
5.3Recommended accessories
In order to assemble the product, the need the following accessories that are
not included in the delivery contents and that you can order from Bosch Rexroth:
Table 4: Recommended accessories
Component
Material number
Interface cable RS232, length 3 m
R900776897
USB RS232 converter
R901066684
Cable set VT17220-1X/HNC100-3X, length 2 m,
for analog signals (connection X2A1) and digital
position transducers (connection X8M1) with
HD plug and open breakout cable for:
VT-HNC100-1-3X
R901189300
Cable set VT17220-1X/HNC100-3X, length 2 m,
for analog signals (connection X2A) and digital
position transducers (connection X8M) with
FK MC plug and open breakout cable for:
VT-HNC100-C-3X
R901189302
16/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Assembly
5.4Assembling the VT-HNC100...3X/S...
CAUTION!
Risk of personal injuries and material damage!
Assembly of the product requires basic electrical knowledge.
ff The product may only be assembled by qualified personnel
(see chapter 2.3).
Assemble the VT-HNC100...3X/S... on a top hat rail as follows:
ff De-energize the relevant part of the system.
ff Carefully engage the housing back side of the VT-HNC100...3X/S... on a top
hat rail. The mechanical contact points on the elastic back wall of the
VT-HNC100...3X/S... allow for a safe seat on the top hat rail and the connection of the housing with the control cabinet's earthing system.
Hang up
Press down
Lock
Fig. 1: Assembling the VT-HNC100...3X/S... on the top hat rail
Contact points
Top hat rail 35 mm
TH 35-7,5 or TH 35-15
to EN 60715
Fig. 2: Contact points of the VT-HNC100...3X/S... for assembly on top hat rail
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
17/24
Assembly
CAUTION!
Risk of injuries when assembling under voltage!
If you do not switch off voltage supply before assembling the product, you may
get injured, destroy the product or damage system components.
ff Always switch off power supply to the relevant system component before assembling the product.
CAUTION!
Risk of personal injuries and material damage!
Incorrect energy supply may lead to uncontrolled valve positions. These could
possibly result in malfunctions or failure of the VT-HNC100...3X/S... and cause
injuries.
ff Exclusively use a power pack with safe electrical isolation.
ff Always comply with the country-specific regulations.
CAUTION!
Connecting or disconnecting plugs under voltage will destroy the unit!
Connecting or disconnecting plugs under voltage causes high potential differences which can destroy the unit.
ff Switch off power supply to the relevant system component before assembling
the unit or when connecting and disconnecting plugs.
CAUTION!
Short-circuit or failures due to penetrating humidity and contamination
The housing of the VT-HNC100...3X/S... is perforated. Contamination and liquids
may easily enter and cause failures or short-circuits!
Safe functioning of the VT-HNC100...3X/S... is thus no longer ensured.
ff Always provide for absolute cleanness when working on
the VT-HNC100...3X/S....
ff For the pin assignments of the VT-HNC100...3X/S... please refer to chapter 4.1.
18/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Maintenance
6Maintenance
6.1Cleaning and care
CAUTION!
The housing of the VT-HNC100...3X/S... is perforated. Contamination and
liquids may easily enter and cause failures!
Safe functioning of the VT-HNC100...3X/S... is thus no longer ensured.
ff Always provide for absolute cleanness when working on
the VT-HNC100...3X/S....
ff Only use a dry and dust-free cloth for all cleaning works.
CAUTION!
Damage to the surface due to solvents and aggressive cleaning agents!
Aggressive detergents may damage the VT-HNC100...3X/S... and let it age faster.
ff Never use solvents or aggressive detergents.
For cleaning and maintenance proceed as follows:
ff Perform a visual inspection for checking the tight seat of all lines and screws.
ff Check all plug-in and clamping connections of the VT-HNC100...3X/S... for
correct seat and damage at least once per year.
ff Check lines for breakage and squeezing. Have damaged or defective lines
exchanged immediately!
ff Clean housing parts with a dry and dust-free cloth.
6.2Repair
The VT-HNC100...3X/S... can only be exchanged as whole unit. For safety
reasons, modifications at the VT-HNC100...3X/S... performed to one's own
authority are not admissible! Repair and service works may only be performed by
Bosch Rexroth AG. For repair and service works, send the unit to the service address specified in chapter 10.1.
Bosch Rexroth AG
RE 30159-B/10.11 | VT-HNC100...3X/S...
19/24
Disassembly and replacement
7 Disassembly and replacement
7.1Required tools
No tools required.
7.2Preparing disassembly
Decommission the entire system as described in the overall system instructions.
The system must in any case be brought into a safe condition, stopped, depressurized and de-energized and secured against re-start.
WARNING!
Risk of injuries when disassembling under pressure and with electrical
voltage applied!
If you do not de-pressurize and de-energize the system before disassembling
the product, you may get injured and the product or system components may be
damaged.
ff Make sure that the relevant system components are depressurized and deenergized.
7.3Disassembling the VT-HNC100...3X/S...
Proceed as follows to disassemble the VT-HNC100...3X/S...:
ff Pull off the connection lines and plugs.
ff Release the VT-HNC100...3X/S... from the top hat rail.
Press Down
Fig. 5: VT-HNC100...3X/S... disassembly from the top hat rail
Pull out from below
by pressing on top
20/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Disassembly and replacement / disposal
7.4Preparing storage and further use
Proceed as follows in order to prepare the VT-HNC100...3X/S... for storage and
further use:
ff Only use the original packing for storage.
ff Observe the admissible storage temperature range that is specified
in RE 30159.
ff Protect against dust and humidity.
8Disposal
8.1Environmental protection
Careless disposal of the VT-HNC100...3X/S... may lead to environmental
contamination.
ff Thus, dispose of the VT-HNC100...3X/S... in accordance with the national
regulations in your country!
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
21/24
Troubleshooting
9Troubleshooting
9.1How to proceed for troubleshooting
• Always act systematically and targeted, even under pressure of time. Random
and imprudent disassembly and readjustment of settings might result in the inability to restore the original error cause.
• First get a general idea of how the product works in conjunction with the entire system.
• Try to find out whether the product has worked properly in conjunction with the
entire system before the troubles occurred first.
• Try to determine any changes of the entire system in which the product
is integrated:
–– Were there changes to the product's operating conditions or operating range?
–– Were there any changes (e.g. retrofitting) or repair works on the entire system
(machine/system, electrics, control) or on the product? If yes: Which?
–– Was the product or machine used as intended?
–– How did the malfunction appear?
–– Try to get a clear idea of the error cause. If necessary, as the direct
(machine) operator.
• For troubleshooting, use the “Indraworks” diagnosis possibilities.
Optionally, the diagnosis and the error messages can be read out via field bus.
If you should not be able to remedy an occurred error, please contact one of the
addresses that you can find under www.boschrexroth.com or in the address directory in chapter 10.1.
22/24
Bosch Rexroth AG
VT-HNC100...3X/S... | RE 30159-B/10.11
Appendix
10Appendix
10.1 Address directory
Contact person for support
Bosch Rexroth AG
97816 Lohr am Main
Germany
Phone +49 (93 52) 18-11 32
Fax
+49 (93 52) 18-33 63
E-mail: support.nc-system[email protected]
Contact person for service
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str.8
97816 Lohr am Main
Germany
E-mail: [email protected]
RE 30159-B/10.11 | VT-HNC100...3X/S...
Bosch Rexroth AG
23/24
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone
Fax
+49 (0) 93 52 / 18 0
+49 (0) 93 52 / 18 23 58
[email protected]
www.boschrexroth.de
Subject to change without notice
Printed in Germany
RE 30159-B/10.11
History of the
VT-HACD-...-2X product family
User program BODAC and firmware
RE 30543-10-Z/04.12
Replaces: 02.11
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 3/20
Content
1
General ....................................................................................................... 5
2
Bodac.......................................................................................................... 6
2.1
Overview...................................................................................................... 6
2.2
Bugfixes ....................................................................................................... 7
General ........................................................................................................................ 7
HACD-1x Family........................................................................................................... 7
Communication ............................................................................................................ 7
Controller parameters................................................................................................... 7
Table ............................................................................................................................ 8
2.3
New features................................................................................................ 9
General ........................................................................................................................ 9
Manufactury.................................................................................................................. 9
Feedback Encoder ....................................................................................................... 9
Communication ............................................................................................................ 9
Controller parameters................................................................................................. 10
3
Firmware HACD-2x .................................................................................. 11
3.1
Overview.................................................................................................... 11
Package solutions ...................................................................................................... 11
Package information................................................................................................... 12
3.2
Bugfixes ..................................................................................................... 13
General ...................................................................................................................... 13
Manufactury................................................................................................................ 13
Feedback encoder...................................................................................................... 13
Internal Flags.............................................................................................................. 13
Communication .......................................................................................................... 13
Controller parameters................................................................................................. 14
Controller structure..................................................................................................... 14
4/20
Bosch Rexroth AG | Hydraulics
3.3
History VT-HACD-2x product family | RE 30543-10-Z/04.12
New Features ............................................................................................ 16
General ...................................................................................................................... 16
Analog I/O .................................................................................................................. 16
Manufactury................................................................................................................ 16
Feedback encoder...................................................................................................... 16
Communication .......................................................................................................... 16
Controller parameters................................................................................................. 17
Tables ........................................................................................................................ 18
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 5/20
General
1
General
This documentation describes the versions of the windows program Bodac and the
firmware of the products based on HACD-2x technology.
Within the document there are several specific terms that are defined as follows:
Software (SW):
windows based program Bodac which is used to configure and
service the HACD family
Firmware (FW):
The actual software which resides within the controller
Firmware package: Is a set of firmware modules necessary for a controller operate
Bugfixes:
Incremental correction or improvements in the software/firmware
functionality
Package solutions: Overview of the bugfixes and new features in a firmware
package
Package information: Overview of the firmware modules in a firmware package.
6/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Bodac
2
Bodac
2.1
Overview
Version
Date
Bugfixes
New features
Bodac2.03.00.00
01.04.2012
General
Controller
parameters
Table
General
Manufactury
Feedback Encoder
Communication
Controller parameters
Bodac2.02.01.00
23.02.2011
General
HACD-1x Family
General
Communication
Bodac2.02.00.00
20.12.2010
General
Communication
Table
Communication
Bodac2.01.00.00
21.04.2010
Start of production
Start of production
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 7/20
Bodac
2.2
Bugfixes
General
Bodac2.03.00.00

Optimizing the download process of packages (pkg2) onto an HACD-2x
Bodac2.02.01.00

Remedied download problems with firmware packages: A message “Unable
to erase sector” appeared before programming Ethernet firmware.

Remove an unnecessary shown “access violation” message that was
displayed when opening the card information or the SSI screen
Bodac2.02.00.00

Remedied download problems with Ethernet firmware: A message “Unable to
erase sector” appeared after having downloaded the bootstrap.
HACD-1x Family
Bodac2.02.01.00


Bugfix for downloading a parameterfile onto an HACD-1x
Correct the reading and writing of valves parameters of a VSPD: Fault was
noticeable in the user profiles.
Communication
Bodac2.02.00.00

Local Bus: ID-Adaption in screen „Search Cards“: There has been an offset of
one.

Remove an unnecessary shown warning message that was displayed when a
user opened the status screen of another card via Local Bus

Extend the maximal allowed entries of the busmanager from 16 to 32

Gray out the Ethernet Device Name subjected to the DIL switches
Controller parameters
Bodac2.03.00.00


When an HACD-1x parameterfile will be opened in an HACD-2x the velocity
of 5000 Units/sec remains 5000 Units/sec instead of the maximum of 100000
Units/sec.
Correct the structure overview when “Preset” or “Table” is selected.
8/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Bodac
Table
Bodac2.03.00.00

Fix problems caused by opening plt-files including digital signals
Bodac2.02.00.00

Fix problems caused by opening plt-files
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 9/20
Bodac
2.3
New features
General
Bodac2.03.00.00

Put all firmware modules to a firmware package together and do the resulting
changes in Bodac:
o
New card information screen
o
Adapt the package download
o
Add the attachment of which firmware package was used to newly
created parameterfiles
o
Allow only firmware packages with the suffix “.pkg2” to be
downloaded to an HACD with Bodac

Put the HACD-2x to the beginning when searching for offline applications

The “Send Email to support” functionality was simplified.
Bodac2.02.01.00

The screen Bodac>Tools>Preferences>Security>Login now accepts
passwords with a maximum of 20 characters

Gray out the “Continue” button while downloading a package to prevent user
handling errors

Allow the “Internal flags” screen to be put onto any security level in
Bodac>Tools>Preferences>Security>Configure Screens
Manufactury
Bodac2.03.00.00

Implementation of an additional check, if an HACD-2x hardware has got the
corresponding HACD-2x software in it.
Feedback Encoder
Bodac2.03.00.00

Allow single ended incremental encoder to be used, which is available with
hardware version 21a or newer
Communication
Bodac2.03.00.00

Allow ethernet capable VT-HACD-3-2x to communicate not only serial, but
also over an Ethernet service interface with Bodac
o
New “Search cards” screen
o
Move and shorten the address space of the bus code
o
Renew the Bodac>Tools>Preferences>COM Interface screen
10/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Bodac
o
Cards that are connected over the local bus, can now also be found
and configured over TCP/IP.

Remove the parameters “Ratio C1”, “Ratio C2” and “Ratio C3” from the
busmanager.

Actualize the Multi-Ethernet (METH) screen
Bodac2.02.01.00

Ethernet Hardware/Transmit/Receive: Changes will now only be accepted
after a card reset. Otherwise there will appear a warning message

Ethernet Hardware: Various conditions are checked regarding the
DeviceName, IP, Gateway and Subnet. (see also chapter „IP-Address and
device name“ unter RE 30543-04-Z / RE 30543-05-Z)
Bodac2.02.00.00

Add new Profinet functionality
Controller parameters
Bodac2.03.00.00

Expand the parameter editor with the parameters „Stop CMD“ and “Limit IControl”

Expand the parameter summary with the parameters “Stop CMD” and “Limit IControl”
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 11/20
Firmware HACD-2x
3
Firmware HACD-2x
3.1
Overview
Package solutions
Version
Date
Bugfixes
New features
Manufactury
Feedback encoder
Communication
Controller parameters
FWA-HACD-2x-FW0-20V06
FWA-HACD-2x-FWP-20V06
FWA-HACD-2x-FWE-20V06
FWA-HACD-2x-FWN-20V06
01.04.2012
FWA-HACD-2x-FW0-20V04_0014
FWA-HACD-2x-FWP-20V04_0014
FWA-HACD-2x-FWE-20V04_0014
FWA-HACD-2x-FWN-20V04_0014
29.11.2011
Communication
Controller parameters
Controller structure
General
Communication
Tables
FWA-HACD-2x-FW0-20V04_0012
FWA-HACD-2x-FWP-20V04_0012
FWA-HACD-2x-FWE-20V04_0012
FWA-HACD-2x-FWN-20V04_0012
18.10.2011
General
Internal Flags
Controller structure
Analog I/O
FWA-HACD-2x-FW0-20V04_0010
FWA-HACD-2x-FWP-20V04_0010
FWA-HACD-2x-FWE-20V04_0010
FWA-HACD-2x-FWN-20V04_0010
22.07.2011
Manufactury
FWA-HACD-2x-FW0-20V04_0008
FWA-HACD-2x-FWP-20V04_0008
FWA-HACD-2x-FWE-20V04_0008
FWA-HACD-2x-FWN-20V04_0008
14.04.2011
Feedback encoder
FWA-HACD-2x-FW0-20V04_0006
FWA-HACD-2x-FWP-20V04_0006
FWA-HACD-2x-FWE-20V04_0006
FWA-HACD-2x-FWN-20V04_0006
01.03.2011
Feedback encoder
Communication
Controller parameters
FWA-HACD-2x-FW0-20V04_0004
FWA-HACD-2x-FWP-20V04_0004
FWA-HACD-2x-FWE-20V04_0004
FWA-HACD-2x-FWN-20V04_0004
02.02.2011
Communication
FWA-HACD-2x-FW0-20V04
FWA-HACD-2x-FWP-20V04
FWA-HACD-2x-FWE-20V04
FWA-HACD-2x-FWN-20V04
20.12.2010
General
Communication
Controller parameters
Communication
FWA-HACD-2x-FW0-20V02
FWA-HACD-2x-FWP-20V02
FWA-HACD-2x-FWE-20V02
21.04.2010
Start of production
Start of production
12/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Firmware HACD-2x
Package information
Version
Hardware
Contents
Bodac
Ethernet
FWA-HACD-2x-FW0-20V06
FWA-HACD-2x-FWP-20V06
FWA-HACD-2x-FWE-20V06
FWA-HACD-2x-FWN-20V06
21a
bot.04.00.00
MER.04.00.00
Ixx.04.00.00
Pxx.04.00.00
VAL.02.00.00
Bodac2.03.00.00
LW 0.6.3.0
FW 0.B.B.0
FWA-HACD-2x-FW*20V04_0014 /
FWA-HACD-2x-FWN20V04_0014
20b
/
20a
bot.03.03.00
MER.03.06.00
Ixx.03.03.00
Pxx.03.01.00
VAL.02.00.00
Bodac2.02.01.00
LW 0.6.3.0
FW 0.B.9.0
FWA-HACD-2x-FW*20V04_0012 /
FWA-HACD-2x-FWN20V04_0012
20b
/
20a
bot.03.02.00
MER.03.05.00
INO.03.01.00/Ixx.03.02.00
Pxx.03.00.00
VAL.02.00.00
Bodac2.02.01.00
LW 0.5.1.0
FW 0.A.1.0
FWA-HACD-2x-FW*20V04_0010 /
FWA-HACD-2x-FWN20V04_0010
20b
/
20a
bot.03.01.00
MER.03.04.00
INO.03.01.00/Ixx.03.02.00
Pxx.03.00.00
VAL.02.00.00
Bodac2.02.01.00
LW 0.5.1.0
FW 0.A.1.0
FWA-HACD-2x-FW*20V04_0008 /
FWA-HACD-2x-FWN20V04_0008
20b
/
20a
bot.03.00.00
MER.03.04.00
INO.03.01.00/Ixx.03.02.00
Pxx.03.00.00
VAL.02.00.00
Bodac2.02.01.00
LW 0.5.1.0
FW 0.A.1.0
FWA-HACD-2x-FW*20V04_0006 /
FWA-HACD-2x-FWN20V04_0006
20b
/
20a
bot.03.00.00
MER.03.03.00
INO.03.01.00/Ixx.03.02.00
Pxx.03.00.00
VAL.02.00.00
Bodac2.02.01.00
LW 0.5.1.0
FW 0.A.1.0
FWA-HACD-2x-FW*20V04_0004 /
FWA-HACD-2x-FWN20V04_0004
20b
/
20a
bot.03.00.00
MER.03.00.00
Ixx.03.01.00
Pxx.03.00.00
VAL.02.00.00
Bodac2.02.01.00
LW 0.5.1.0
FW 0.A.1.0
FWA-HACD-2x-FW0-20V04
FWA-HACD-2x-FWP-20V04
FWA-HACD-2x-FWE-20V04
FWA-HACD-2x-FWN-20V04
20b
20b
20b
20a
bot.03.00.00
MER.03.00.00
Ixx.03.00.00
Pxx.03.00.00
VAL.02.00.00
Bodac2.02.00.00
LW 0.5.1.0
FW 0.A.1.0
20b
bot.02.01.00
MER.02.00.00
Ixx.02.00.00
Pxx.02.00.00
VAL.02.00.00
Bodac2.01.00.00
LW 0.4.A.0
FW 0.9.1.3
FWA-HACD-2x-FW*-20V02
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 13/20
Firmware HACD-2x
3.2
Bugfixes
General
FWA-HACD-2x-FWx-20V04_0012

Remedied download problems with Ethernet Logicware
FWA-HACD-2x-FWx-20V04

Remedied download problems with Ethernet Firmware
Manufactury
FWA-HACD-2x-FWx-20V04_0010

Calibration of current output AO1 will now be at 19 instead of 20mA
Feedback encoder
FWA-HACD-2x-FWx-20V04_0008

Correct SSI-velocity value at enable low
FWA-HACD-2x-FWx-20V04_0006

Set the SSI feedback values to zero at cablebreak

Remove SSI fault that was shown at enable with an binary SSI encoder

Correct the binary SSI feedback values

Expand the interpretation of the busparameter “Set dig. FB to zero” for SSI
encoder 1 and 2
Internal Flags
FWA-HACD-2x-FWx-20V04_0012

Correct the internal flags after a block change
Communication
FWA-HACD-2x-FWx-20V04_0014


Bug fix: Profinet input and output modules won’t be recognized under certain
circumstances:
o
only if the power of the HACD is turned on after or at the same time
as the plc.
o
only if the addresses of the input and output modules are lying
within the process image of the plc.
o
only if the plc enters the STOP-mode, if it recognizes the power-off
HACD
Bug fix: A bustrigger at issue won’t be recognized after toggling the enable signal.
14/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Firmware HACD-2x
FWA-HACD-2x-FWx-20V04_0006

Expand the interpretation of the busparameter “Set dig. FB to zero” for SSI
encoder 1 and 2

Correct the Businitfault and the Ethernet Watchdog

Correct the device name assignment by the SPS

Adapt the max value of the busparameter “Bustrigger”
FWA-HACD-2x-FWx-20V04_0004

Bugfix for the bustransfer of active damping and output edit parameters
FWA-HACD-2x-FWx-20V04

Actualized IP address by DHCP usage

Gray out the Ethernet Device Name subjected to the DIL switches

Improve fault handling, if the Ethernet master has not configured all modules.
Do not enter cyclic communication and stay in configuration mode.

Improve the handling of the bus fault

Adjust the internal Ethernet watchdog time

Bugfix for 1 Byte read and write commands over Profibus DPV1 (acyclic)

Extend the maximal allowed entries of the busmanager from 16 to 32
Controller parameters
FWA-HACD-2x-FWx-20V04_0014

Correct the conversion of the HACD-1x parameters „s-ramp start“ and „sramp end“ into the HACD-2x parameters „acceleration“ and „deceleration“
FWA-HACD-2x-FWx-20V04_0006

Correct parameter interpretation of LS2/LS3 in the parameter editor
FWA-HACD-2x-FWx-20V04

Correct the FeedForward scaling

Realize T1 Lag without decimals

Set T1 Lag default value to 640 Hz

Set factory setting of constant CON 1 to zero.

Correct handling of the Loop error debounce time
Controller structure
FWA-HACD-2x-FWx-20V04_0014

Remove Bus-Option as external dwelltime, because it’s not possible.
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 15/20
Firmware HACD-2x
FWA-HACD-2x-FWx-20V04_0012

Sporadic peaks in the DT1(LFB) signal are fixed.
16/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Firmware HACD-2x
3.3
New Features
General
FWA-HACD-2x-FWx-20V06

Put all firmware moduls to a firmware package together
FWA-HACD-2x-FWx-20V04_0014


Check address at firmware download
Limit access to the FPGA-flash on the Ethernet daughterboard; only
Logicware and Firmware can now be exchanged.
Analog I/O
FWA-HACD-2x-FWx-20V04_0012

Improve the quality of the analog input signals
Manufactury
FWA-HACD-2x-FWx-20V06

Implementation of an additional check, if an HACD-2x hardware has got the
corresponding HACD-2x software in it.
Feedback encoder
FWA-HACD-2x-FWx-20V06

Allow single-ended incremental encoder to be used, which is available with
hardware version 21a or newer
Communication
FWA-HACD-2x-FWx-20V06

Allow ethernet capable VT-HACD-3-2x to communicate not only serial, but
also over an Ethernet service interface with Bodac
o
Move and shorten the address space of the bus code
o
Divide the bus communication “EtherNet/IP” or “PROFINET” from
the service communication “TCP”
o
Cards that are connected over the local bus, can now also be found
and configured over TCP/IP.

The consolidation of the GSDML files with the HNC100-3x and MAC8 causes
incompatibility to the already delivered GSDML files.

Only with EtherNet/IP: Add functionality “Save all Parameters over the bus”
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 17/20
Firmware HACD-2x
FWA-HACD-2x-FWx-20V04_0014

Actualize the Multi-Ethernet (METH) screen

Allow an out-of-box reset over Ethernet

Observe the min and max values of bus parameters (Profibus, EtherNet/IP
and Profinet)

All error states will be shown flashing red on the Ethernet MS (Module status)
LED

Check if BusIDs (slot/index) are valid for acyclic and cyclic reading and writing
(Profibus, EtherNet/IP and Profinet)

If the DIL-switch is used to determine the IP address, then the IP-suite cannot
be changed over the PLC or Bodac anymore.

Show actual IP-address in Bodac when using DHCP already in the state
COMINIT instead of showing it in COMACTV (EtherNet/IP and Profinet)

After power-on stay in the state COMCFG instead of the state SYSRDY as
long as the firmware checksum is calculated (EtherNet/IP and Profinet)

Activate Ethernet Watchdog

After an ethernet capable card has reached the state COMACTV, cyclic and
acyclic transmit data will be set invalid, if the card went back to bootstrap for an
firmware download for example.

Receive data will be ignored in an ethernet capable HACD which is in the
state COMACTV, as long as the card went back to bootstrap for a firmware
download for example.

Change state of ethernet capable HACD from COMACTV, COMRDY or
COMINIT to the state COMCFG, if the card went back to bootstrap for an
firmware download for example.

Only with EtherNet/IP: Allow access to the single table points by using the
classes 0xC5 and 0xC6

Allow access to the table setup parameters over the bus (Profibus,
EtherNet/IP and Profinet)
FWA-HACD-2x-FWx-20V04

Add new Profinet functionality (cyclic and acyclic) including Profinet alarms

Activate control of the Ethernet MS (Module status) LED

Add checksum check of the Ethernet Firmware after power-on and wait for the
result before entering cyclic communication

Implement coherency check of the ethernet objects chosen by a user, like the
IP address or the device name

Expand the desciption of the Ethernet CI_StateFlags in the Multi-Ethernet
(METH) screen
Controller parameters
FWA-HACD-2x-FWx-20V06

Expand the parameter editor with the parameters „Stop CMD“ and „Limit IControl“
18/20
Bosch Rexroth AG | Hydraulics
History VT-HACD-2x product family | RE 30543-10-Z/04.12
Firmware HACD-2x
Tables
FWA-HACD-2x-FWx-20V04_0014

Only with EtherNet/IP: Allow access to the single table points by using the
classes 0xC5 and 0xC6

Allow access to the table setup parameters over the bus (Profibus,
EtherNet/IP and Profinet)
RE 30543-10-Z/04.12 | History VT-HACD-2x product family
Hydraulics | Bosch Rexroth AG 19/20
Firmware HACD-2x
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
[email protected]
www.boschrexroth.com
© This document, as well as the
data, specifications and other
information set forth in it, are
the exclusive property of Bosch
Rexroth AG. It may not be reproduced or given to third parties
without its consent.
The data specified above only
serve to describe the product. No
statements concerning a certain
condition or suitability for a certain
application can be derived from
our information. The information
given does not release the user
from the obligation of own judgment and verification. It must be
remembered that our products
are subject to a natural process of
wear and aging.
Printed in Germany
RE 30543-10-Z/04.12
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