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.