Bosch Rexroth NYCe 4000 User manual

NYCe 4000
Multi-axis motion control system
Hardware System Manual
Project Planning Manual
R911337671
Edition 18

NYCe 4000
Multi-axis motion control system
Hardware System Manual
Project Planning Manual
DOK-NY4000-HW***SYSTEM-PR18-EN-E
RS-eb2ca56b361ca3f60a6846a501caac28-18-en-US-9
Edition Release Date Notes
DOK-NY4000-HW***SYSTEM-PR01-EN-
E
09/2012 First edition
DOK-NY4000-HW***SYSTEM-PR02-EN-
E
01/2013 2nd edition
DOK-NY4000-HW***SYSTEM-PR03-EN-
E
09/2013 3rd edition
DOK-NY4000-HW***SYSTEM-PR04-EN-
E
06/2014 4th edition
DOK-NY4000-HW***SYSTEM-PR05-EN-
E
03/2015 5th edition
DOK-NY4000-HW***SYSTEM-PR06-EN-
E
04/2016 6th edition
DOK-NY4000-HW***SYSTEM-PR07-EN-
E
11/2016 7th edition
DOK-NY4000-HW***SYSTEM-PR08-EN-
E
12/2017 8th edition
DOK-NY4000-HW***SYSTEM-PR09-EN-
E
03/2018 9th edition
DOK-NY4000-HW***SYSTEM-PR10-EN-
E
07/2018 10th edition
DOK-NY4000-HW***SYSTEM-PR11-EN-
E
03/2019 11th edition
DOK-NY4000-HW***SYSTEM-PR12-EN-
E
08/2019 12th edition
DOK-NY4000-HW***SYSTEM-PR13-EN-
E
06/2020 13th edition
DOK-NY4000-HW***SYSTEM-PR14-EN-
E
07/2020 14th edition
DOK-NY4000-HW***SYSTEM-PR15-EN-
E
03/2021 15th edition
DOK-NY4000-HW***SYSTEM-PR16-EN-
E
08/2021 16th edition
DOK-NY4000-HW***SYSTEM-PR17-EN-
E
11/2021 17th edition
DOK-NY4000-HW***SYSTEM-PR18-EN-
E
04/2022 18th edition
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
NYCe 4000 Multi-axis motion control system Hardware Sys‐
tem Manual

List of trademarks FireWire is a registered trademark of Apple® Computer Inc.
Products in this publication are referred to by their general trade names. In
most, if not all cases, these designations are claimed as trademarks or
registered trademarks of their respective companies.
Copyright © Bosch Rexroth AG 2022
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial
property rights.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this
documentation and the availability of the product.
Published by Bosch Rexroth AG
P.O. Box 7170 ■ 5605 JD Eindhoven ■ The Netherlands
http://www.boschrexroth.com

Table of Contents
Page
1 Introduction.................................................................................................................... 1
1.1 Purpose of Documentation..................................................................................................................... 1
1.2 General Information................................................................................................................................ 1
1.3 Cross reference component name, order number, short name.............................................................. 2
1.3.1 Introduction.......................................................................................................................................... 2
1.3.2 NYCe 4000 system housings.............................................................................................................. 2
1.3.3 NYCe 4000 MCUs, drive, digital I/O and SERCOS III Master modules.............................................. 3
1.3.4 NYCe 4000 accessories...................................................................................................................... 3
2 Safety Instructions for Electric Drives and Controls....................................................... 7
2.1 Definitions of Terms................................................................................................................................ 7
2.2 Explanation of Signal Words and the Safety Alert Symbol..................................................................... 8
2.3 General Information................................................................................................................................ 9
2.3.1 Using the Safety Instructions and Passing Them on to Others........................................................... 9
2.3.2 Requirements for Safe Use................................................................................................................. 9
2.3.3 Hazards by Improper Use.................................................................................................................. 11
2.4 Instructions with Regard to Specific Dangers....................................................................................... 11
2.4.1 Protection against Contact with Electrical Parts and Housings......................................................... 11
2.4.2 Safety Extra-Low Voltage as Protection Against Electric Shock....................................................... 13
2.4.3 Protection against Dangerous Movements........................................................................................ 13
2.4.4 Protection against Magnetic and Electromagnetic Fields during Operation and Mounting............... 16
2.4.5 Protection against Contact with Hot Parts......................................................................................... 16
2.4.6 Protection during Handling and Mounting......................................................................................... 17
3 Important Directions for Use........................................................................................ 19
3.1 Appropriate Use.................................................................................................................................... 19
3.2 Areas of use and Application................................................................................................................ 19
3.3 Inappropriate Use................................................................................................................................. 20
3.4 Acceptance tests and approvals........................................................................................................... 20
3.4.1 Introduction........................................................................................................................................ 20
3.4.2 Low voltage directive......................................................................................................................... 20
3.4.3 EMC directive.................................................................................................................................... 21
3.4.4 CE...................................................................................................................................................... 21
3.4.5 UL...................................................................................................................................................... 22
3.4.6 RoHS................................................................................................................................................. 22
4 System Overview......................................................................................................... 23
4.1 Hardware Architecture.......................................................................................................................... 23
4.2 Motion Node Modules........................................................................................................................... 24
4.3 System housing with backplane........................................................................................................... 26
5 NY4110: MCU Module................................................................................................. 29
5.1 Overview............................................................................................................................................... 29
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5.2 Module identification............................................................................................................................. 30
5.3 Module dimensions............................................................................................................................... 31
5.4 Field Diagnostics.................................................................................................................................. 31
5.5 24V System power supply.................................................................................................................... 32
5.6 Service Mode and Stop Axes Inputs..................................................................................................... 33
5.7 FW1, FW2, FW3 connection information.............................................................................................. 34
5.8 Installation requirements....................................................................................................................... 35
5.8.1 Before you begin............................................................................................................................... 35
5.8.2 Cable connections............................................................................................................................. 35
5.9 IT-Security............................................................................................................................................ 35
6 NY4112: Ethernet MCU Module.................................................................................. 37
6.1 Overview............................................................................................................................................... 37
6.2 Module identification............................................................................................................................. 37
6.3 Module dimensions............................................................................................................................... 38
6.4 Field Diagnostics.................................................................................................................................. 39
6.5 24V System power supply.................................................................................................................... 39
6.6 Service Mode and Stop Axes Inputs..................................................................................................... 40
6.7 ETH1, ETH2 connection information.................................................................................................... 42
6.8 Installation requirements....................................................................................................................... 42
6.8.1 Before you begin............................................................................................................................... 42
6.8.2 Cable connections............................................................................................................................. 42
6.8.3 Environmental conditions.................................................................................................................. 43
6.9 IT-Security............................................................................................................................................ 43
7 NY4114: Ethernet MCU Module.................................................................................. 45
7.1 Overview............................................................................................................................................... 45
7.2 Module identification............................................................................................................................. 46
7.3 Module dimensions............................................................................................................................... 47
7.4 Field Diagnostics.................................................................................................................................. 47
7.5 24V System power supply.................................................................................................................... 49
7.6 Service Mode and Stop Axes Inputs..................................................................................................... 49
7.7 ETH1, ETH2, ETH3 connection information......................................................................................... 51
7.8 USB connection information................................................................................................................. 51
7.9 Installation requirements....................................................................................................................... 52
7.9.1 Before you begin............................................................................................................................... 52
7.9.2 Cable connections............................................................................................................................. 52
7.9.3 Environmental conditions.................................................................................................................. 52
7.10 System software recovery.................................................................................................................... 53
7.11 IT-Security............................................................................................................................................ 56
8 NY4120 and NY4120/10: PWM Drive Module............................................................. 59
8.1 Overview............................................................................................................................................... 59
8.2 Module identification............................................................................................................................. 60
8.3 Module dimensions............................................................................................................................... 61
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8.4 Field Diagnostics.................................................................................................................................. 61
8.5 Power switch on/off precautions........................................................................................................... 62
8.6 I/O Connector....................................................................................................................................... 63
8.7 Analog Inputs........................................................................................................................................ 64
8.8 Analog Outputs..................................................................................................................................... 66
8.9 Digital Inputs......................................................................................................................................... 68
8.10 Digital Outputs...................................................................................................................................... 71
8.11 Digital High Speed Inputs and Outputs................................................................................................. 74
8.12 5 Volt Digital Inputs............................................................................................................................... 76
8.13 Encoder Inputs and Encoder Power Supply......................................................................................... 77
8.14 Drive Output.......................................................................................................................................... 78
8.14.1 Characteristics................................................................................................................................... 78
8.14.2 Motor types........................................................................................................................................ 79
8.14.3 Connection information...................................................................................................................... 80
8.15 Drive Power.......................................................................................................................................... 81
9 NY4125: 5-axis low power PWM Drive Module........................................................... 83
9.1 Overview............................................................................................................................................... 83
9.2 Module identification............................................................................................................................. 84
9.3 Module dimensions............................................................................................................................... 85
9.4 Field Diagnostics.................................................................................................................................. 85
9.5 Power switch on/off precautions........................................................................................................... 86
9.6 I/O Connector....................................................................................................................................... 87
9.7 Digital Inputs......................................................................................................................................... 88
9.8 Digital Outputs...................................................................................................................................... 90
9.9 Digital High Speed Inputs and Outputs................................................................................................. 93
9.10 TTL Digital Inputs.................................................................................................................................. 95
9.11 Encoder Inputs and Encoder Power Supply......................................................................................... 96
9.12 Drive Output.......................................................................................................................................... 96
9.12.1 Characteristics................................................................................................................................... 96
9.12.2 Motor types........................................................................................................................................ 97
9.12.3 Connection information...................................................................................................................... 98
9.13 Drive Power.......................................................................................................................................... 99
10 NY4130: DC Drive Module......................................................................................... 101
10.1 Overview............................................................................................................................................. 101
10.2 Module identification........................................................................................................................... 102
10.3 Module dimensions............................................................................................................................. 103
10.4 Field Diagnostics................................................................................................................................ 103
10.5 Power switch on/off precautions......................................................................................................... 104
10.6 I/O Connector..................................................................................................................................... 105
10.7 Analog Inputs...................................................................................................................................... 106
10.8 Analog Outputs................................................................................................................................... 108
10.9 Digital Inputs....................................................................................................................................... 110
10.10 Digital Outputs.................................................................................................................................... 113
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10.11 Digital High Speed Inputs and Outputs............................................................................................... 116
10.12 5 Volt Digital Inputs............................................................................................................................. 117
10.13 Encoder Inputs and Encoder Power Supply....................................................................................... 119
10.14 Drive Output........................................................................................................................................ 119
10.14.1 Characteristics................................................................................................................................. 119
10.14.2 Motor type........................................................................................................................................ 120
10.14.3 Connection information.................................................................................................................... 120
10.15 Drive Power........................................................................................................................................ 122
10.16 Installation requirements..................................................................................................................... 123
11 NY4140: High Voltage Drive Module......................................................................... 125
11.1 Overview............................................................................................................................................. 125
11.2 Module identification........................................................................................................................... 126
11.3 Module dimensions............................................................................................................................. 127
11.4 Field Diagnostics................................................................................................................................ 127
11.5 Power switch on/off precautions......................................................................................................... 128
11.6 I/O Connector..................................................................................................................................... 129
11.7 Analog Inputs...................................................................................................................................... 130
11.8 Analog Outputs................................................................................................................................... 132
11.9 Digital Inputs....................................................................................................................................... 134
11.10 Digital Outputs.................................................................................................................................... 137
11.11 Digital High Speed Inputs and Outputs............................................................................................... 140
11.12 5 Volt Digital Inputs............................................................................................................................. 141
11.13 Encoder Inputs and Encoder Power Supply....................................................................................... 143
11.14 Drive Output........................................................................................................................................ 143
11.14.1 Characteristics................................................................................................................................. 143
11.14.2 Motor types...................................................................................................................................... 144
11.14.3 Connection information.................................................................................................................... 145
11.15 Drive Power........................................................................................................................................ 146
12 NY4150 and NY4150/10: SERCOS III Master Module.............................................. 147
12.1 Overview............................................................................................................................................. 147
12.2 Module identification........................................................................................................................... 148
12.3 Module dimensions............................................................................................................................. 149
12.4 Field Diagnostics................................................................................................................................ 150
12.5 Supported NYCe 4000 functionality with NY4150.............................................................................. 151
12.6 I/O Connector..................................................................................................................................... 152
12.7 Analog Inputs...................................................................................................................................... 153
12.8 Digital Outputs.................................................................................................................................... 153
12.9 Connection NY4150 – IndraDrive....................................................................................................... 153
12.10 Installation requirements..................................................................................................................... 154
13 Encoders.................................................................................................................... 157
13.1 Introduction......................................................................................................................................... 157
13.2 Encoder power supply switch............................................................................................................. 158
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13.3 Timing aspects of the control loop...................................................................................................... 159
13.4 Encoders and BLDC motor with +5 Volt Hall sensors........................................................................ 164
13.5 Quadrature encoder............................................................................................................................ 165
13.6 Analog position sensor....................................................................................................................... 170
13.7 Rexroth MSM incremental encoder.................................................................................................... 172
13.8 Rexroth MSM absolute encoder......................................................................................................... 175
13.9 Sanyo Denki absolute encoder........................................................................................................... 181
13.10 EnDat2.2 encoder............................................................................................................................... 186
13.11 SinCos encoder.................................................................................................................................. 188
13.12 EnDat2.1 encoder............................................................................................................................... 192
13.13 Hiperface encoder.............................................................................................................................. 196
13.14 NY4199 SinCos Option module for SinCos based encoders............................................................. 200
13.14.1 Overview.......................................................................................................................................... 200
13.14.2 Module identification........................................................................................................................ 201
13.14.3 Module dimensions.......................................................................................................................... 202
13.14.4 Installation instructions for the NY4199 SinCos Option module...................................................... 203
14 Network...................................................................................................................... 205
14.1 Introduction......................................................................................................................................... 205
14.2 IEEE 1394b multi-node configuration NY4110 MCU.......................................................................... 205
14.3 IEEE 802.3 multi-node configuration NY4112 MCU........................................................................... 206
14.3.1 Introduction...................................................................................................................................... 206
14.3.2 Direct cable connection between PC and NY4112-based node(s)................................................. 207
14.3.3 Connection between PC and NY4112-based node using a switch................................................. 207
14.3.4 DHCP support................................................................................................................................. 208
14.4 IEEE 802.3 multi-node configuration NY4114 MCU........................................................................... 208
14.4.1 Introduction...................................................................................................................................... 208
14.4.2 Direct cable connection between PC and NY4114-based node(s)................................................. 209
14.4.3 Connection between PC and NY4114-based node using a switch................................................. 209
14.4.4 DHCP support................................................................................................................................. 210
15 NYCe 4000 Hardware Glossary................................................................................. 211
16 Drive power precautions for NY412x/NY4140........................................................... 213
16.1 Drive Power Filtering for NY412x/NY4140......................................................................................... 213
16.1.1 Introduction...................................................................................................................................... 213
16.1.2 Filtering on NY40x3, NY4074 and NY40x2 system housings......................................................... 214
16.1.3 Filtering on NY40x0 system housings............................................................................................. 214
16.2 Motor Chokes..................................................................................................................................... 215
16.3 Regenerative Braking......................................................................................................................... 216
17 Environmental Conditions.......................................................................................... 217
17.1 Thermal............................................................................................................................................... 217
17.2 Shock and Vibration............................................................................................................................ 217
17.3 Electromagnetic Compatibility............................................................................................................ 217
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17.4 Environment........................................................................................................................................ 217
17.5 Derating Conditions............................................................................................................................ 218
17.5.1 Introduction...................................................................................................................................... 218
17.5.2 Forced cooled systems, NY4120..................................................................................................... 218
17.5.3 Convection cooled systems, NY4120.............................................................................................. 219
17.5.4 Forced cooled systems, NY4125..................................................................................................... 220
17.5.5 Convection cooled systems, NY4125.............................................................................................. 221
17.5.6 Forced cooled systems, NY4130..................................................................................................... 222
17.5.7 Convection cooled systems, NY4130.............................................................................................. 222
17.5.8 Forced cooled systems, NY4140..................................................................................................... 223
17.5.9 Convection cooled systems, NY4140.............................................................................................. 223
18 Cleaning, Disposal and Environmental Protection..................................................... 227
18.1 Cleaning.............................................................................................................................................. 227
18.2 Disposal.............................................................................................................................................. 227
18.3 Environmental Protection.................................................................................................................... 227
19 Service and Support.................................................................................................. 229
19.1 Helpdesk............................................................................................................................................. 229
19.2 Service-Hotline................................................................................................................................... 229
19.3 Internet................................................................................................................................................ 229
19.4 Before contacting us........................................................................................................................... 229
20 Appendix - EU declaration of conformity - modules................................................... 231
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1 Introduction
1.1 Purpose of Documentation
This NYCe 4000 Hardware System Manual provides information about the
modules of the NYCe 4000 system. You can find on the internet (http://
www.boschrexroth.com/various/utilities/mediadirectory/index.jsp?
oid=326148&language=en-GB) the latest version of this manual. Click the
links "Electric Drives and Controls" → "Control Units" → "Controls" →
NYCe 4000" on the mentioned webpage.
This Hardware System Manual is intended for electrical engineers, system
engineers and users of the NYCe 4000 system. They can use this document
as a reference for connecting and installing a specific NYCe 4000 system.
Personal injury and property damage can be
caused by incorrect usage of the modules,
machines and installations!
WARNING
Take the content of this Hardware System Manual into account.
This Hardware System Manual, among other things, contains:
● specifications for the components of the drive system
● configuration of the drive system components
● arrangement of the components in the control cabinet
● electromagnetic compatibility (EMC)
● connections of the components in the drive system
1.2 General Information
Damage can be caused to the NYCe 4000 module or circuit boards if
electrostatic charge present in people and/or tools is discharged across them.
Therefore, please note the following information:
Electrostatic charges can cause damage to
electronic components and interfere with their
operational safety!
WARNING
Objects that come into contact with components and circuit boards must be
discharged by means of grounding. Otherwise errors may occur when
triggering motors and moving elements.
Such objects include:
● the copper bit when soldering
● the human body (discharge through touching a conductive, grounded
item)
● parts and tools (placing on a conductive support)
Components sensitive to electrostatic discharge may only be stored or
dispatched in conductive packaging.
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