Bosch Rexroth VT-HNC100 3X/S Series Instruction manual

RE 30159, edition: 2012-03, Bosch Rexroth AG
Digital drive controller
for hydraulic axes
withsercos interface
Contents
Features 2
Ordering code 3
Software project planning 4
Overview of the controller functions 4
System overview 5
System overview, interfaces 6
Technical data 7
Pin assignment 12
Unit dimensions 13
Project planning / maintenance instructions /
additional information 14
 Component series 3X
RE 30159
Edition: 2012-03
Replaces: 09.11
H7644
Type VT-HNC100.../S

2/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG, RE 30159, edition: 2012-03
Features
The VT-HNC100...3X/S digital drive controller complies
with the specific requirements for closed-loop control
of hydraulic linear drives.
It is designed for being used in rough industrial environ-
ments as regards interference immunity, mechanical
vibration, shock, and climate resistance.
Areas of application
 Machine tools
 Bending machines
Technology functions
 Positioning
 Velocity controller:
– Controlled
– Regulated
 Force controller
 Substitutional closed-loop control
 Moving without following error
 Quadrant error correction
Hydraulic axes
 Measurement system:
– Incremental TTL 5V
– SSI transducer
– EnDat 2.2
– Analog 0 to ±10 V
 Actuating variable output voltage or current
 Freely configurable controller variants
– Position / force / velocity controller
– Substitutional closed-loop control (position/force)
Programming
 Via the control with IndraWorks
Operation
 IndraWorks
Process connection
 Digital inputs and outputs,
 Analog inputs and outputs,
 sercos II or sercos III to communicate with a supe-
rior control system
Assembly
 Top hat rail 35 mm
CE conformity
 CE conformity according to EMC Directive 2004/108/EC
and EMVG (Act on electromagnetic compatibility of
operating media) from February 26, 2008
Harmonized standards used:
EN 61000-6-2:2005
EN 61000-6-3:2007
More information
www.boschrexroth.com/hnc100

Digital drive controller | VT-HNC100.../S 3/14
RE 30159, edition: 2012-03, Bosch Rexroth AG
Ordering code
01
Se
ri
al
u
ni
t
V
T-HN
C
1
00
02
Versions for an h
y
draulic axi
s
Com
p
act
C
Sta
n
da
r
d
1
03
Component series 30 to 39
(
30 to 39: Unchan
g
ed technical data and pin assi
g
nment
)
3X
04
B
us
co
nn
ectio
n
sercos II
/
sercos III 1
)
S
05
P
os
i
t
i
o
n
t
r
a
n
sducer
Incremental
/
EnDat 2.2
/
SSI
(
standard
)
2
)
I
EnDat 2.2
/
SS
I
(
onl
y
in connection with Compact version
)
2
)
S
06
sercos II
(
onl
y
in connection with Compact version
)
00
sercos III
(
onl
y
in connection with Standard version
)
30
07
O
p
t
i
o
n
E
Wi
thout
000
VT-HN
C
1
00
–
–
3X
/
S
–
–
/
01
02
03
04
05
06
0
7
Available variants
Type Material number
VT-HNC100-C-3X/S-S-00/000 R901112919
VT-HNC100-1-3X/S-I-30/000 R901234133
1) Ethernet service interface only in connection with sercosIII
2) Can be selected by means of the IndraWorks PC program
Included in the scope of delivery:
Mating connector for
 X1S (type Phoenix Mini Combicon 3-pole),
 X2D (type Phoenix Micro Combicon 8-pole and/or Phoenix Mini Combicon 12-pole),
 X2A (type Phoenix Micro Combicon 8-pole and/or HD-SUB 15-pole),
 X8M (type Phoenix Micro Combicon 8-pole and/or HD-SUB 15-pole)
Recommended accessories (can be ordered separately)
Denomination 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 X2A) or digital position measurement systems (connection X8M) with
HDconnector and open breakout cable for VT-HNC100-1-3X
R901189300
Cable set VT17220-1X/HNC100-3X length 2 m,
for analog signals (connection X2A) or digital position measurement systems (connection X8M) with
FK-MC connector and open breakout cable for VT-HNC100-C-3X
R901189302

4/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG, RE 30159, edition: 2012-03
Software project planning
Project planning
Developing application-specific data sets forms the basis
for the function of the VT-HNC100...3X/S. These data sets
are generated on the PC and sent to the VT-HNC100...3X/S
using a serial Ethernet interface. This software parameter-
ization is implemented according to fix steps:
1. Depending on the assignment, the inputs and outputs
and the parameters used are defined.
2. The parameters (selection of transducers and control-
lers) are defined.
3. The data are sent to the VT-HNC100...3X/S.
4. The settings are optimized at the machine.
PC program "IndraWorks"
To implement the project planning tasks, the "IndraWorks"
PC program is available to the user. It serves for parameter-
izing, setting, and diagnosing the VT-HNC100...3X/S.
Scope of service:
 Comfortable dialog functions for setting the parameters
online or offline
 Dialog window for the online setting of the param-
etervalues
 Various options for the display of the process variables
Notice:
The PC program "IndraWorks" is not covered by the scope
of delivery.
Queries: [e-mail]
Overview of the controller functions
Position controller:
 PDT1 controller
 Linear amplification characteristic curve
 Direction-dependant gain adjustment
 Adaptation of the valve characteristic curve
 Valve characteristic diagram
 Fine positioning
 Residual voltage principle
 Compensation of zero point errors
 State feedback via:
– Force,
– Position
 Command value feedforward
Force controller:
 PIDT1 controller
 I share switchable via window
 Differential pressure evaluation
 Additive velocity addition
Velocity controller:
 PI controller
 I share switchable via window
Monitoring functions:
 Dynamic following error monitoring
 Traversing range limits (electronic end switches)
 Cable break monitoring for position transducers
 Cable break monitoring for sensors with out-
put4to20mA

Digital drive controller | VT-HNC100.../S 5/14
RE 30159, edition: 2012-03, Bosch Rexroth AG
System overview
IndraDrive HNC100-C-3X/S
IndraMotion MTX
(CNC control)
IndraWorks
(engineering environment)
Example
Hydraulic axesElectrical axes

6/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG, RE 30159, edition: 2012-03
7
1
2
6
3
5
4
X7S1
RX SERCOS TX
X7S2
X3C
X8M
X1S
encoder
RS232
X2A
AIO
X2D
DIO
power
GND
GND
18 30V
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
3.3V RUN BUS
HNC100
System overview, interfaces
Superior control system
Possible interfaces with the VT-HNC100...3X/S:
 Analog signals
 Digital inputs/outputs
 Serial interface
 Bus systems (sercos II or sercos III)
Example of sercos II:
VT-HNC100-C-3X/S with one hydraulic cylinder axis
1Single-rod cylinder
2Integrated position measurement system
3Continuous control valve with integrated control electronics
4VT-HNC100...3X/S
5Connection cable
6Pressure transducer
7Sandwich plate shut-off valve
(with connector switching amplifier)

Digital drive controller | VT-HNC100.../S 7/14
RE 30159, edition: 2012-03, Bosch Rexroth AG
Operating voltage 1) UB18 to 30 VDC
Current consumption at 24 VDC Approx. 200 mA (observe additional current consumption for con-
nected sensors/actuators)
Processor 32 bit power PC
Analog inputs (AI):
– Voltage input (reference to AGND - Analog ground)
• Channel number 1
• Input voltage UEMax. +12 V to –12 V (+10 V to –10 V measurable)
• Input resistance RE200 k ± 5 %
• Resolution 5 mV
• Non-linearity < 0.2 %
• Calibration tolerance
2) Max. 40 mV (with factory settings)
– Current inputs
• Channel number 2
• Input current IE4 mA to 20 mA
• Leakage current IV0.1 to 0.4 % (with 100  between pin 2 and/or pin 3 (Cin1+ and/or
Cin2+) and "AGND"
• Resolution 5 µA
– Voltage supply for analog sensors
via the VT-HNC100-C-3X/S U, I UB, max. 100 mA at X2A, pin 7 (+24 Vsens)
Analog outputs (AO):
– Voltage outputs
• Channel number 2
• Output voltage Unom –10 V to +10 V (max. –10.7 V to +10.7 V)
• Output current Imax ±10 mA
• Load Rmin 1 k
– Resolution 1.25 mV
– Non-linearity
• In the range –9.5 V to +9.5 V < 0.1 %
• In the range –10 V to –9.5 V and +9.5 V to +10 V < 0.2 %
Technical data VT-HNC100-C-3X/S (Compact)
1) If a 24 V transducer supply is implemented directly via the
VT-HNC100...3X/S (supply voltage is looped in), the transducer
specification has to be observed.
2) If the factory settings are insufficient, the measurement technol-
ogy can be calibrated on site via software in a system-specific way.

8/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG, RE 30159, edition: 2012-03
Bus interface sercos II
Switching inputs (DI) Quantity 4
Logic level log 0 (low) ≤ 5 V; log 1 (high) ≥ 10 V to UB,
Ie= 20 mA with UB= 24 V
Connection Flexible conductor up to 1.5 mm2
Switching outputs (DO) Quantity 2
Logic level log 0 (low) ≤ 2 V; log 1 (high) ≤ UB; Imax = 20 mA,
maximum load capacity C = 0.047 µF
Connection Flexible conductor up to 1.5 mm2
Reference potential for all signals DGND
Digital position transducers (encoders):
– SSI transducer (Due to the higher control quality, an SSI transducer
with clock synchronization should be used.)
• Coding Gray-Code / binary code
• Data width Adjustable 12 to 28 bits
• Line receiver / line driver RS485
• Voltage supply via the VT-HNC100-C-3X/S U, I UB, max. 200 mA at X8M, pin 7 (+24 Venc)
– Position transducer, EnDat 2.2
• Interface (clock and data) according to RS485
• Voltage supply via the VT-HNC100-C-3X/S U, I 5.25 V ±1 %, max. 400mA at X8M, pin6 (+5Venc)
3.6 to 5.25 V must be applied to the transducer.
• Resolution Minimum 10 nm or higher
Reference potential for all signals EGND
Dimensions See page 13
Assembly Top hat rail TH 35-7.5 or TH 35-15 according to EN 60715
Admissible operating temperature range 0 to 50 °C
Storage temperature range –20 to +70 °C
Protection class according to EN 60529:1991 IP 20
Weight m440 g
CE conformity See page 2
Further technical details upon request.
Notice:
For information on the environment simulation testing for the areas EMC (electro-magnetic compatibility), climate and
mechanical load, see data sheet 30139-U.
Technical data VT-HNC100-C-3X/S (Compact) continued

Digital drive controller | VT-HNC100.../S 9/14
RE 30159, edition: 2012-03, Bosch Rexroth AG
Operating voltage 1) UB18 to 30 VDC
Current consumption at 24 VDC CPU card approx. 200 mA
Per axis approx. 100 mA (observe additional current consumption
for connected sensors/actuators)
Processor 32 bit power PC
Analog inputs (AI) per axis electronics:
– Voltage inputs (differential inputs)
• Channel number 2
• Input voltage UEMax. +12 V to –12 V (+10 V to –10 V measurable)
• Input resistance RE200 k ± 5 %
• Resolution 5 mV
• Non-linearity < 0.2 %
• Calibration tolerance
2) Max. 40 mV (with factory settings)
– Current inputs
• Channel number 2
• Input current IE4 mA to 20 mA
• Leakage current IV0.1 to 0.4 %
• Resolution 5 µA
– Voltage supply for analog sensors
via the VT-HNC100-1-3X/S U, I UB,max. 200 mA at X2A, pin 14 (+24 Vsens)
Analog outputs (AO) per axis electronics: 3) 2
– Non-linearity
• In the range –9.5 V to +9.5 V < 0.1 %
• In the range –10 V to –9.5 V and +9.5 V to +10 V < 0.2 %
– Voltage output
• Output voltage Unom –10 V to +10 V (max. –10.7 V to +10.7 V)
• Output current Imax ±10 mA
• Load Rmin 1 k
• Residual ripple ±60 mV (without noise)
• Resolution 1.25 mV
– Current output
• Output current standardized Inom 4 mA to 20 mA
• Load Rmax 500 
• Resolution 0.625 A
Bus interface sercos III
Switching inputs (DI) and/or outputs (DO) per
axis electronics (adjustable via software) Quantity 11
Switching inputs (DI) Logic level log 0 (low) ≤ 5 V; log 1 (high) ≥ 10 V to UB,
Ie= 20 mA with UB= 24 V
Connection Flexible conductor up to 1.5 mm2
Switching outputs (DO) Logic level log 0 (low) ≤ 2 V; log 1 (high) ≤ UB; Imax = 20 mA,
maximum load capacity C = 0.047 µF
Connection Flexible conductor up to 1.5 mm2
Reference potential for all signals DGND
Technical data VT-HNC100-1-3X/S (1-axis version)
1) If a 24 V transducer supply is implemented directly via the
VT-HNC100-1-3X/S (supply voltage is looped in), the transducer
specification has to be observed.
2) If the factory settings are insufficient, the measurement technol-
ogy can be calibrated on site via software in a system-specific way.
3) Configurable as current or voltage output.

10/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG, RE 30159, edition: 2012-03
Digital position transducers (encoder)
per axis electronics:
– Position transducer, incremental
(transducer with TTL output)
• Input voltage log 0 0 to 1 V
log 1 2.8 to 5.5 V
• Input current log 0 –0.8 mA (with 0 V)
log 1 0.8 mA (with 5 V)
• Max. frequency referring to Ua1 fmax 250 kHz
• Voltage supply via the VT-HNC100...3X/S U, I 5.25 V ±1 %, max. 400 mA at X8M1, pin 12 (+5 Venc)
– SSI transducer (Due to the higher control quality, an SSI transducer
with clock synchronization should be used.)
• Coding Gray-Code / binary code
• Data width Adjustable 12 to 28 bits
• Line receiver / line driver RS485
• Voltage supply via the
VT-HNC100...3X/S U, I UB,max. 500 mA at X8M1, pin 14 (+24 Venc)
– Position transducer, EnDat 2.2
• Interface (clock and data) according to RS 485
• Voltage supply via the VT-HNC100...3X/S U, I 5.25 V ±1 %, max. 400 mA at X8M1, pin 12 (+5 Venc)
3.6 to 5.25 V must be applied to the transducer.
• Resolution Minimum 10 nm or higher
Analog position transducer (encoder):
• Input voltage UEMax. +12 V to –12 V (+10 V to –10 V measurable)
• Input resistance RE> 10 M
• Resolution 5 mV
• Non-linearity < 0.2 %
• Calibration tolerance
1) Max. 40 mV (with factory settings)
• Voltage supply via the VT-HNC100...3X/S U, I +10 V ± 25 mV, max. 20 mA at X8M1, pin 13 (+10 Vref)
Reference potential for all signals EGND
Dimensions See page 13
Assembly Top hat rail TH 35-7.5 or TH 35-15 according to EN 60715
Admissible operating temperature range 0 to 50 °C
Storage temperature range –20 to +70 °C
Protection class according to EN 60529:1991 IP 20
Weight m585 g
CE conformity See page 2
Further technical details upon request.
Technical data VT-HNC100-...-3X (1-axis version), continued
Notice:
For information on the environment simulation testing for the areas EMC (electro-magnetic compatibility), climate and
mechanical load, see data sheet 30139-U.
1) If the factory settings are insufficient, the measurement
technology can be calibrated on site via software in a system-
specific way.

Digital drive controller | VT-HNC100.../S 11/14
RE 30159, edition: 2012-03, Bosch Rexroth AG
X7S1
RX SERCOS TX
X7S2
X3C
X8M
X1S
encoder
RS232
X2A
AIO
X2D
DIO
power
GND
GND
18 30V
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
3.3V RUN BUS
HNC100
Pin assignment VT-HNC100-C-3X/S... (Compact with sercos II)
X8M Encoder
Pin SSI EnDat 2.2
8 Shield Shield
7 24 Venc
6 +5 V
5 – Clk – Clk
4 + Clk + Clk
3 – Data – Data
2 + Data + Data
1 EGND
X2D DIO (Digital)
Pin
8 Shield
7 OUT2
6 OUT1
5 IN 4
4 IN 3
3 IN 2
2 IN 1
1 DGND
X2A AIO (Analog)
Pin
8 Shield
7 24 Vsens
6 Vout1 +
5 Vout2 +
4 Vin 1
3 Cin2 +
2 Cin1 +
1 AGND
Notice:
The pins marked with "reserved" are reserved and
must not be connected!
X7 sercos II
S1 TX
S2 RX
X3C RS232
Pin
1
2 TxD
3 RxD
4 Reserved
5 GND
6 Reserved
7 Reserved
8 Reserved
9
X1S Power
Pin
1 GND
2 GND
3 18 – 30 V

12/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG, RE 30159, edition: 2012-03
X3C
X1S
X7P/C
DP/CANopen RS232
CPU
power
GND
GND
18 30V
3.3V RUN BUS
X8M 1
X2D1
X2A1
AIO encoder
slot1
GND
HNC100
L
L
S
S
X7E2
X7E1
NS
MS
Pin assignment VT-HNC100-1-3X/S... (1-axis version with sercos III)
Notices:
The pins marked with
"reserved" are reserved and
must not be connected!
Slot 1
X2D1
DIO
(Digital)
Pin
1 I/O 1
2 I/O 2
3 I/O 3
4 I/O 4
5 I/O 5
6 I/O 6
7 I/O 7
8 I/O 8
9 I/O 9
10 I/O 10
11 I/O 11
12 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
Slot 1
X8M1
Encoder
Incremental EnDat 2.2 SSI Analog
Pin
1 – B (Inc)
2 + CLK + CLK
3 + R (Inc)
4 – R (Inc)
5 + A (Inc)
6 – A (Inc)
7 – CLK – CLK
8 + B (Inc)
9 – Data – Data
10 EGND EGND EGND EGND
11 + Data + Data
12 +5 Venc +5 Venc
13 +10 Vref
14 +24 Venc
15 Vimp1
X7E1, X7E2
sercos III connection
PROFIBUS DP or CANopen (connection X7P/C) are not available with the ser-
cosversion.
X3C RS232
Pin
1
2 TxD
3 RxD
4 Reserved
5 GND
6 Reserved
7 Reserved
8 Reserved
9
X1S Power
Pin
1 GND
2 GND
3 18 – 30 V

120
34 118
124
6
2,5
X7S1
RX SERCOS TX
X7S2
X3C
X8M
X1S
encoder
RS232
X2A
AIO
X2D
DIO
power
GND
GND
18 30V
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
3.3V RUN BUS
HNC100
Unit dimensions (dimensions in mm)
Assembly on top hat rail TH 35-7.5 or TH 35-15 according to EN 60715
VT-HNC100-C-3X/S...
120
71 118
124
6
2,5
X3C
X1S
X7P/C
DP/CANopen RS232
CPU
power
GND
GND
18 30V
3.3V RUN BUS
X8M 1
X2D1
X2A1
AIO encoder
slot1
GND
HNC100
L
L
S
S
X7E2
X7E1
NS
MS
Assembly on top hat rail TH 35-7.5 or TH 35-15 according to EN 60715
VT-HNC100-1-3X/S...
Digital drive controller | VT-HNC100.../S 13/14
RE 30159, edition: 2012-03, Bosch Rexroth AG

14/14 VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone [phone]/18-0
[e-mail]
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 repro-
duced 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, RE 30159, edition: 2012-03
Commissioning software and documentation on the Internet: www.boschrexroth.com/HNC100
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 accepted. The user must transfer all appropriate user parameters and programs again.
Notices:
 The VT-HNC100...3X/S does not support rotary drives
 Electric signals taken out via control electronics (e.g. "No error" signal) must not be used for switching safety-
relevant machine functions! (See also the European standard "Safety requirements for fluid power systems and
their components - Hydraulics", EN 982.)
 If electro-magnetic interference is to be anticipated, suitable measures must be taken to ensure the function
(depending on the application, e.g. shielding, filtration)!
In order to satisfy the requirements of the CE mark, a cable of category 7 (cat. 7 according to ISO/IEC 11801)
must be used for the sercos III communication.
 The upper and lower ventilation slots must not be concealed by adjacent units in order to provide for suffi-
cientcooling.
Product documentation for VT-HNC100...3X/S
Product information 09956
Data sheet 30159
Operating instructions 30159-B
Functional description 30159-FK
Parameter description 30159-PA
Environmental compatibility statement 30139-U
Project planning / maintenance instructions / additional information

Digital drive controller | VT-HNC100.../S
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone [phone]/18-0
[e-mail]
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 repro-
duced 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 30159, edition: 2012-03, Bosch Rexroth AG

VT-HNC100.../S | Digital drive controller
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone [phone]/18-0
[e-mail]
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 repro-
duced 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, RE 30159, edition: 2012-03