Re29014 2006-05 PDF

Proportional directional valve, RE 29014/06.
05 1/18
Replaces: RE 29014-02-M
direct operated,
with pQ functionality
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 Features

Contents Page – Direct operated 3-way proportional valve with integrated digital
Features 1 closed-loop control electronics type IAC-P, for controlling a
pressure in port A
Ordering code 2
– Completely matched unit, consisting of a position-controlled
Standard types, symbols 2
valve, pressure sensor and field bus interface
Structure, function, section 3
– Actuation via proportional solenoid with central thread and
Technical data 4 and 5 detachable coil
Electrical connection, pin assignment 5 to 7 – Closed-loop position controlled valve spool
Characteristic curves 8 to 13 – Integrated pressure sensor plate (optional)
Unit dimensions 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
Engineering / maintenance notes / supplementary information 18 Profibus DP
– Separate component plugs for power supply and bus interfac-
ing
– Fast commissioning by means of PC and commissioning soft-
ware 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 Further details

Size 6 in clear text
Component series 20 to 29 = 2X Interface A6 or F6
(20 to 29: unchanged installation and connection dimensions) A6 = ±10 VDC
F6 = 4 to 20 mA
Nominal flow
P → A 10 l/min, A → T 20 l/min =1 Bus interface
P → A 20 l/min, A → T 20 l/min =2 C= CAN bus DS - 408
P= Profibus DP V0/V1
FKM = rectangular profile rings suitable for mineral oils
(HL, HLP) to DIN 51524 =V Supply voltage
24 = 24 VDC
Pressure stage of the integrated pressure
sensor
3= Nominal pressure 50 bar
STW 0196 1X 1 V 24 *
With integrated digital electronics and pQ functionality Further details in clear

Size 10 text
Component series 10 to 19 =1X Interface A6 or F6
(10 to 19: unchanged installation and connection dimensions) A6 = ±10 VDC
F6 = 4 to 20 mA
Nominal flow
P → A 65 l/min, Bus interface
A → T 60 l/min, C= CANBus DS - 408
B → T 60 l/min =1 P= Profibus DP V0/V1
FKM = rectangular profile rings suitable for mineral oils Supply voltage
(HL, HLP) to DIN 51524 =V 24 = 24 VDC
Pressure stage of the integrated pressure
sensor
Standard types, symbols
Type Size Material no. Symbol
STW 0195-2X/1V5-24CF6 6 R900767353 A B

STW 0195-2X/1V8-24CF6 6 R901018622 G
a P b
STW 0195-2X/2V5-24CF6 6 R901006499
STW 0195-2X/2V8-24CF6 6 R901006529 P T
A B
G
STW 0196-1X/1V5-24CF6 10 R900705778
STW 0196-1X/1V8-24CF6 10 R901021786 a P b
P T
RE 29014/06.05 STW0195, STW0196 Hydraulics Bosch Rexroth AG 3/18
Structure, function, section

Structure The digital integrated control electronics allow the following
The IAC-P valve basically consists of: faults to be detected: (Diagnosis)
– Housing (1) with mounting face – Cable break of pressure sensor supply cable (6)
– Control spool (2) with compression spring (3) – Undervoltage
– Solenoid and pressure tube (4) with central thread – Break of position transducer cable (5)
– Position transducer (5) – Communication error
– Pressure sensor (6) – Watchdog
– Integrated digital closed-loop control electronics IAC-P (7) – Cable break of command value inputs
with bus interface (X2) and central plug-in connector (X1).
The following additional functions are available:
Functional description – Pressure ramp
– With de-energised solenoid (4), spool position A → T – Internal command value profile
(with STW 0196-1X/1 additionally B → T) – Enable function analogue / digital
– Functions: – Fault output 24 V
• Open-loop flow control (Q)
PC program WINPED
• Closed-loop pressure control (p)
For performing engineering work and parameterising the IAC-
• Alternating closed-loop control p/Q
P valves, the user can utilize the commissioning software
– The command value can be fed forward alternatively via an WINPED (see Accessories).
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 - Diagnosis
bus (X2, X3). - Comfortable data administration on a PC
– The controller parameters are adjusted via the field bus (X2, - PC operating systems: Windows 2000 or Windows XP
X3).
– 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
> 12 mA 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
Functional section of STW 0195–2X

X2 7 X1
X3 only avail-
able in con-
junction with X3
Profibus
A B
Note: 6 3 2 1 4 5
Draining of the tank line must be prevented. In the case of a correspond-
ing installation situation, install a suitable pre-load valve.
Technical data (for applications outside these parameters, please consult us!)
General STW195 STW196
Installation orientation 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) 50 bar bar 50
Ports P, A, B with sensor 160 bar bar 160
250 bar bar 250
50 bar bar 50
Port T with sensor 160 bar bar 160
250 bar bar 210
Nominal flow qV nom Spool 1 Spool 2
at ∆p = 5 bar from P → A l/min 65
(see also flow characteristic 10 20
curves from page 10) from A → T l/min 20 20 A → T, B → T 60
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 °C –20 … +80, preferably +40 … +50
Viscosity range mm2/s 20 … 380, preferably 30 … 46
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
Response sensitivity % ≤ 0.05
Zero point drift %10 K ≤ 0.15
%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 Vss 2
Current consumption Imax A 2
Impulse current A 3
Command value signals mA 4 … 20 or via CAN bus
Duty cycle 3) % 100
Max. coil temperature 4) °C up to 150
Type of protection of the valve to EN 60529 IP 65 with cable socket correctly mounted and locked
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 malfunc-
tion 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 the supply voltage to the valve only, when required for the functional sequence of the machine.
4) Due to the surface temperatures of solenoid coils, observe European standards EN 563 and EN 982.
Sensors STW 195 (size 6) and STW 196 (size 10)

Measuring range p bar 50 160 250
N
Overload protection p bar 120 320 500
max
Burst pressure p bar 550 800 1200
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 Pin assignment of interface A6 Pin assignment of interface F6
wire col-
our 1)
1 1 24 VDC (u(t) = 19.4 V … 35 V), Imax = 1.7 A (for output stage)
2 2 0V load zero, reference for pins 1 and 9
3 white Enable input 9 ... 35 V enable ON
4 yellow ±10 V command value Q Ri > 50 kΩ 4...20 mA command value Q Ri = 100 Ω
5 green Reference for command values Q and P
6 violet ± 10 V actual value Q 4...20 mA actual value Q (load impedance max. 300 Ω)
7 pink 0 … 10 V command value P Ri > 50 kΩ 4...20 mA command value P Ri = 100 Ω
8 red 0 … 10 V actual value P 4...20 mA actual value P (load impedance 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 body
X1
Connect shield to PE on the supply side only!
4 5
3 10 6
1) Litz wire colour of connecting cable for cable socket with cable set 9 11
(see Accessories ) 2 7
1 8
Component plug assignment X2, CAN bus, (coding A), M12 x 1, 5-pin, male
Pin Assignment Baud rate kbit/s 20 to 1000

X2
Bus address 1 to 127 3
1 n.c.
CAN-speciﬁc settings:
2 n.c. 2
The baud rate and the identiﬁer must be set via the
3 CAN_GND bus system.
4 5
4 CAN_H
1
5 CAN_L
X2
Component plug-in connector pin assignment for Profibus DP, “X2“/”X3“ (coding B), 4
M12 x 1, 5-pin, male/female
1
Pin Assignment Baud rate up to 12 MBaud
Bus address 1 to 126 3 5
1 +5V
Setting via DIL switch 2
2 RxD/TxD-N (A-cable)
3 D GND
4 RxD/TxD-P (B-cable) X3
4
5 Shield
The +5-V voltage of the IAC-P is available for an external terminating resistor. 3
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.
Block circuit diagram, integrated control electronics
X2
Profibus Profibus
controller
X3
Aternative
X2
CAN bus
X1
Command value Q 4 I
U A CAN
D controller
Command value p 7 D Actual pressure value
I A A
U D
Actual value Q 6 Output
I PWM U
U stage
p
Actual value p 8 Controller PWM U
I PID
PWM I
U
Enable 3 Output stage
OFF
11 Actual posi- Oscillator

Fault output tion value
D demodulator
A
Valve with inductive positi-

on encoder
Reference for pins Microcontroller =
4; 7 5
≈
Reference for pins EEPROM Flash Cable break
3; 6; 8; 11 10
GND
24V load supply 1
Output stage supply
24V signal supply 9 DC +Ui

–Ui
DC GND
GND 2
Protective con-
PE
ductor
Command value: 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: 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
Characteristic curves of STW 0195-2X/1...
Transient function, STW 0195-2X/1..., A → T
100 0 - 100 100
75 0 - 75 75
Stroke in % →
50 0 - 50 50
25 0 - 25 25
0 0
0 20 40 0 20 40
Time in ms →
Transient function, STW 0195-2X/1..., P → A
100 0 - 100 100
75 0 - 75 75
Stroke in % →
50 0 - 50 50
25 0 - 25 25
0 0
0 20 40 0 20 40
Time in ms →
Transient function, STW 0196-1X/1..., A → T, B → T
100 0 - 100 100
75 0 - 75 75
Stroke in % →
50 0 - 50 50
25 0 - 25 25
0 0
0 40 80 0 40 80
Time in ms →
Transient function, STW 0196-1X/1..., P → A
100 0 - 100 100
75 0 - 75 75
Stroke in % →
50 0 - 50 50
25 0 - 25 25
0 0
0 40 80 0 40 80
Time in ms →
Characteristic curves of STW 0195-2X/1... and STW 0196-1X/1...
Frequency response, STW 0195-2X/1...
10
5 –315
0 –270
Phase angle in ° →
–5 –225
Gain in dB →
±10%
–10 –180 ±25%
±100%
–15 –135
–20 –90
–25 –45
–30 0
1 10 20 30 50 100 200
Frequency in Hz →
Frequency response, STW 0196-1X/1...
5 –315
0 –270
–3
–5 –225
±10%
Gain in dB →
–10 –180
±25%
±100%
–15 –135
–20 –90
–25 –45
–30 0
1 10 20 30 50 100 200
Frequency in Hz →
Performance limit A → T, closed-loop position controlled Performance limit P → A, closed-loop position controlled
120 70
100 60
50
80
Flow in l/min. →
Flow in l/min. →
40
60
30
40
20
20 10
0 0
5 50 100 150 200 250 5 50 100 150 200 250
Pressure differential in bar → Pressure differential in bar →
Flow characteristic curve A → T, ∆p = 5 bar Flow characteristic curve P → A, ∆p = 5 bar
25 12
10
20
8
Flow in l/min. →
Flow in l/min. →
15
6
10
4
5
2
0 0
- 100 -80 -60 -40 -20 0 0 20 40 60 80 100
Command value in % → Command value in % →
120 120
100 100
80 80
Flow in l/min. →
Flow in l/min. →
60 60
40 40
20 20
0 0
5 50 100 150 200 250 5 50 100 150 200 250
Flow characteristic curve A → T, ∆p = 5 bar Flow characteristic curve P → A, ∆p = 5 bar
25 25
20 20
Flow in l/min. →
Flow in l/min. →
15 15
10 10
5 5
0 0
- 100 -80 -60 -40 -20 0 0 20 40 60 80 100

225 250
200 225
200
175
175
150
Flow in l/min. →
Flow in l/min. →
150
125
125
100
100
75
75
50 50
25 25
0 0
5 50 100 150 200 250 5 50 100 150 200 250
Performance limit B → T, closed-loop position controlled Flow characteristic curve A → T, ∆p = 5 bar

200
175 60
150
Flow in l/min. →
Flow in l/min. →
125
40
100
75
20
50
25
0 0
5 50 100 150 200 250 -100 -80 -60 -40 -20 0
Pressure differential in bar → Command value in % →
Flow characteristic curve P → A, ∆p = 5 bar Flow characteristic curve B → T, ∆p = 5 bar
60 60
Flow in l/min. →
Flow in l/min. →
40 40
20 20
0 0
0 20 40 60 80 100 –100 –80 –60 –40 –20 0
Unit dimensions STW 0195-2X/1... (nominal dimensions in mm)
3 4
“X”
118
47
b
32
23
A B 15,1 44
34 69
ca. 35
“X”
268
1 2
T
A B
P
0,01/100mm
15
Rmax 4
8
F1 F2
T
Required surface quality of
mating piece
47
A B
P
F3
F4 G
72
1 Valve housing Subplates to data sheet RE 45052 and valve fixing screws
2 Proportional solenoid “b“ with inductive position trans- must be ordered separately.
ducer
Subplates: G341/01 (G1/4)
3 Integrated digital control electronics
G342/01(G3/8)
4 Nameplate
G502/01(G1/2)
5 Machined valve mounting face
Position of ports to ISO 4401-03-02-0-94
Valve fixing screws:
Deviating from standard:
4 off socket head cap screws
– Ports P, A, B and T Ø8 mm ISO 4762-M5 x 50-10.9
– Bore G is not required, since the valve is not fitted MT = 8.9 Nm
with a pin.
Unit dimensions STW 0196-1X/1... (nominal dimensions in mm)
3 4
”X”
144,6
b
72,5
40
20
40 19,1
69,3
92,2
ca.35 339 ”X”
1 2
P
TA A B TB
5
0,01/100mm
Rmax 4 20 50,8±0,2
32,5±0,2 13
Required surface quality of F1 P F2

mating piece
A B
72
T T1
F4 F3
94
1 Valve housing Subplates to data sheet RE 45052 and valve fixing screws
2 Proportional solenoid “b“ with inductive position trans- must be ordered separately.
ducer
3 Integrated digital control electronics Subplates: G66/01(G3/8)
4 Nameplate G67/01(G1/2)
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
Accessories (not included in the scope of supply)
The following is required for parameterisa- CANopen Profibus DP

tion by means of a PC:
1 Interface converter (USB) VT-ZKO-USB/CA-1-1X/V0/0 VT-ZKO-USB/P-1-1X/V0/0
Mat. no. R901071963 Mat. no. R901071962
2 Commissioning software WINPED
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
1
Accessories, port X1(not included in the scope of supply)
Cable socket for X1

Cable socket to DIN EN 17520-804 • Cable socket without cable (kit) Material no. R900884671
(11-pin + PE), plastic version • 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
5 4
6 3
10
33
7 11 9 2
8 1
90
Accessories, CAN bus (A coding) (not included in the scope of supply)
Description Detail, dimensions Pin pattern, order information

X2 ca. 56
Round plug-in 1
connector,
2
wired by user, 5-
Ø19,6
pin, M12 x 1 4 5
Straight cable 3
socket, metal ver-
sion. Mat. no.: R901076910
(cable diameter 6 - 8 mm)
Accessories, Profibus (B coding) (not included in the scope of supply)
Description Detail, diemnsions Pin pattern, order information

X2 ca. 61
Round plug-in
4
connector, 1
wired by user, 5- 5
Ø19,6
3
pin, M12 x 1 2
Straight cable
plug, metal ver-
sion. Mat. no.: R901075545
X3 ca. 56
Round plug-in
connector, 3 4
wired by user, 5-
Ø19,6
5
1
pin, M12 x 1 2
Straight cable
socket, metal ver-
sion. Mat. no.: R901075550
M12 protective
cap (for cable
socket only) Mat. no.: R901075563
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-rel-
evant machine functions! (See also European standard “safety requirements for fluid power systems and components - hydrau-
lics “, 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 © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
Zum Eisengießer 1 be reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany The data specified above only serve to describe the product. No state-
Phone +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain application
Fax +49 (0) 93 52 / 18-23 58 can be derived from our information. The information given does not
documentation@boschrexroth.de release the user from the obligation of own judgment and verification. It
www.boschrexroth.de must be remembered that our products are subject to a natural process of
wear and aging.
Notes
wear and aging.
Notes
wear and aging.
4/3 proportional directional valve RE 29048/04.08 1/20
with integrated digital electronics

and field bus interface (IFB-P)
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

Content Page – Direct operated proportional directional valve with integrated
Features 1 digital electronics and field bus interface (Integrated Field Bus
IFB-P)
Ordering code 2
– Actuation by proportional solenoids with central thread and
Standard types 2
detachable coil
Symbols 2
– Closed-loop position control of valve spool
Function, section 3
– For subplate mounting: Porting pattern to ISO 4401
Technical data 4
– Analog interface for command and actual value
Integrated electronics (IFB-P) 5 to 7
– Command value (flow) analog or via bus
Characteristic curves 8 to 13
– Variant for CAN bus with CANopen protocol DS 408
Unit dimensions 14 and 15 or PROFIBUS DP
Accessories 16 to 18 – Can be parameterized via bus
Engineering / maintenance notes / supplementary information 19 – 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 *
With integrated digital electronics =F Further details in

and field bus interface clear text
Size 6 =6 Electronics interface
Size 10 = 10 A1 = ±10 VDC
Symbols F1 = 4 to 20 mA
A B
Bus interface
a 0 b a 0 b C = CANBus DS-408
P = PROFIBUS DP V0/V1
P T
Supply voltage
=E 24 = 24 VDC
E1 1) FKM seals
V = Rectangular rings, suitable
for mineral oils (HL, HLP) to DIN 51524
=V 2X = Component series 20 to 29
(20 to 29: unchanged installation
and connection dimensions)
=W
W1
Nominal flow 2)
Size 6
8 l/min = 08 1) With
symbol E1:
16 l/min = 16
P → A: qVmax
32 l/min = 32
P → B: qV/2
Size 10 B → T: qV/2
25 l/min = 25 A → T: qVmax
50 l/min = 50
75 l/min = 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… Type 4WREF . V… Type 4WREF . W…
A B A B A B
G G G
a b a b a b
P T P T P T
RE 29048/04.08 4WREF Hydraulics Bosch Rexroth AG 3/20
Function, section
Structure:
System requirements
The valve basically consists of:
– IBM-PC or compatible system
– Housing (1) with connection face
– Windows 2000 or Windows XP
– Control spool (2) with compression springs (3 and 4) and
spring plates (8 and 9) – 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
Functional description: (see page 19)!
– When solenoids (5 and 6) are de-energized control spool
(2) is brought by compression springs (3 and 4) between The integrated digital electronics allows the following
spring plates (8 and 9) to the central position (in the case of faults to be recognized:
V-spool without spring plate). With V-spools, the mechanical – Undervoltage
zero position is not equal to the hydraulic one. – Cable break of position transducer (7)
– The electronics controls the valve spool position. – Communication error
– The command value can be provided alternatively via an – Watchdog
analog interface (X1) or via the field bus interface (X2, X3).
– Cable break of command value inputs (only in the case of
– The actual value signals are made available via an analog current interface)
interface (X1) and can additionally be read out via the field
The following additional functions are provided:
bus (X2, X3).
– Ramp generator
– The controller parameters can be adjusted via the field bus
– Internal command value profile
PC program WIN-PED (version 6 or higher):
– Enable function digital
The commissioning software WIN-PED helps users solve engi-
neering tasks and parameterize IFB-P valves. – Overlap compensation
– Parameterization – Zero point correction
– Diagnosis
– Convenient data administration on PC
– PC operating systems: Windows 2000 or Windows XP
X1 12 X2
X3
Note: 7 5 10 3 8 1 2 9 4 11 6
Draining of the tank line must be prevented. If the installation situation al-
lows, install a suitable pre-load valve.
General Size 6 Size 10

Weight kg 2.4 6.5
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 – Ports A, B, P bar Up to 315
pressure – Port T bar Up to 210
Nominal flow qVnom at Δp = 10 bar l/min 8; 16; 32 25; 50; 75
See nominal flow characteristic curve from page 8 ff.
Maximum flow (standard valves) l/min 80 180
Hydraulic fluids Mineral oil (HL, HLP) to DIN 51524
Other hydraulic fluids on request
Hydraulic fluid temperature range °C –20 to +70, preferably +40 to +50
Viscosity range mm2/s 20 to 380, preferably 30 to 46
Permissible max. degree of contamination of the Class 20/18/15 1)
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 % ≤ 0.05
(valve spool position control)
Zero point drift of valve spool when %/10 K < 0.15
hydraulic fluid temperature and operating %/100 bar < 0.1
pressure change
Electrical
Lower limit value VDC 19.4
Upper limit value VDC 35
Permissible max. residual ripple Vss 2
Total current consump- Imax A 2
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) % 100
Maximum coil temperature 3) °C Up to 150
Type of protection to EN 60529 IP 65 with plug-in connectors mounted and locked
1) Thecleanliness classes specified for components must be Note!

adhered to in hydraulic systems. Effective filtration prevents For details regarding environment simulation testing in the
malfunction and, at the same time, prolongs the service life fields of EMC (electromagnetic compatibility), climate and
of components. mechanical stress, see RE 29048-U (declaration on environ-
For the selection of filters, see data sheets RE 50070, mental compatibility).
RE 50076 and RE 50081.
2) Do not energize the valve unless this is required for the func-
tional sequence of the machine.
3) Dueto the surface temperatures of solenoid coils observe
European standards EN 563 and EN 982!
Integrated electronics (IFB-P)

Marking and adjustment elements
Rexroth
A: + 24V DC
B: 0V
C: reference actual position A B
D: ±10V/0… 20mA G
signal input
E: reference input a b
F: ±10V/0… 20mA *R901053294*
actual position P T
PE: earth conductor 0000000 00 4WREF6…
0000
A001
1 Material no. 1 2 3 4 5 6
2 Production job order number 5 Type designation
3 Date of production 6 DIL switch for address and baud rate setting
4 Serial number (position B0 on the right-hand side)
Electrical connections and pinout

Component plug pinout X1, 6-pin + PE to DIN EN 175201-804
Signal Contact Pinout of interface A1 Pinout of interface F1
A 24 VDC (u(t) = 19.4 V to 35 V); Imax = 2 A
Supply voltage
B 0 V
Actual value reference potential C Actual value reference potential
D ±10 V command value; Ri > 50 kΩ 4 to 20 mA command value; Ri = 100 Ω
Differential amplifier input
E Command value reference potential
Measurement output F ±10 V actual valve spool value, 4 to 20 mA actual valve spool value,
(limit load 5 mA) load resistance max. 300 Ω
PE Connected to heat sink and valve body
Component plug pinout for CAN bus “X2“/”X3“ (coding A),

M12, 5-pin, male/female X2 X3
3 3
Pin Assignment Baud rate kbit/s 20 to
1000 2 4
1 n.c.
Bus address 1 to 127
2 n.c. 4 5 2 5
CAN-specific settings:
3 CAN_GND The baud rate and the identifier can 1 1
4 CAN_H be set via the bus system or using the
DIL switches.
5 CAN_L
Component plug pinout for PROFIBUS DP, “X2“/”X3“

(coding B), M12, 5-pin, female/male X2 X3
4 4
Pin Assignment Baud rate MBaud up to 12
Bus address 1 to 126 1 3
1 +5 V
Settings by means of DIL switches. 3 5 1 5
2 RxD/TxD-N (A-line)
The +5 V voltage of the IAC-P is
3 D GND used for supplying an external bus 2 2
4 RxD/TxD-P (B-line) terminator (as required).
5 Shield

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

Standard 20 kBaud 1 = standard or
0 0 0 0 0 0 0 0 00 1)
or reprogrammed reprogrammed
0 0 0 0 0 0 0 1 01
to to 20 kBaud 1 to 63
0 0 1 1 1 1 1 1 3F
1 = standard or
0 1 0 0 0 0 0 0 40 125 kBaud
reprogrammed
0 1 0 0 0 0 0 1 41
0 1 1 1 1 1 1 1 7F
1 = standard or
1 0 0 0 0 0 0 0 80 250 kBaud
reprogrammed
1 0 0 0 0 0 0 1 81
1 0 1 1 1 1 1 1 BF
1 = standard or
1 1 0 0 0 0 0 0 C0 500 kBaud
reprogrammed
1 1 0 0 0 0 0 1 C1
1 1 1 1 1 1 1 0 FE
Monitoring mode/
1 1 1 1 1 1 1 1 FF 250 kBaud programming mode
1 = firm
PROFIBUS DP
B7 B6 B5 B4 B3 B2 B1 B0 HEX Address range

0 0 0 0 0 0 0 0 00 1) 125 = standard or reprogrammed
0 0 0 0 0 0 0 1 01
1 to 126
to to
with parameter channel
0 1 1 1 1 1 1 0 7E
1 0 0 0 0 0 0 0 80
1 to 126
to to
without parameter channel
1 1 1 1 1 1 1 0 FE
1 1 1 1 1 1 1 1 FF Monitoring operation address 125
1) Factory setting
B7 B0 B7 B0
With PROFIBUS:
Activation of the bus termination by means of the two lower
ON
ON
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 switches:
Figure on the left: Bus termination not activated
Figure on the right: Bus termination activated
ON
ON
2 1 2 1 (both switches to “ON“)

Block circuit diagram
X2
PROFIBUS PROFIBUS
controller
X3
alternative
X3
CAN bus
X2
Command value of
valve spool position D
U/I A CAN con-
Reference potential D troller
U
E
Output stage B Solenoid b
Actual valve U
spool position F I
Controller PWM
U/I PID
Reference potential PWM
U U
C I
Output stage
OFF Output stage A Solenoid a
D Actual
Microcontroller A position Oscillator
value demodulator Inductive
= position
EEPROM Flash ~ transcuder
Cable break
24V signal
supply A DC +Ui
–Ui
DC GND
GND B
Protective earth
conductor PE
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
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
80
0 – 75 – 0
70
Stroke in % →
60
50 0 – 50 – 0
40
30
0 – 25 – 0
20
10
0 10 20 30 40 0 10 20 30
Time in ms →
Frequency response characteristic curves – spool symbol V

5 –315
0 –270
–3
Amplitude ratio in dB →
–5 –225
–10 –180
–15 –135
–20 –90
Signal ±10 %
–25 –45
Signal ±25 %
–30 0 Signal ±100 %
1 10 20 30 50 100 200
Frequency in Hz →
Flow/load function with max. valve aperture – spool symbol V

200
100 Permissible
80 32 max. flow
16
Flow in l/min →
08
10
P → A / B → T
or
1 P → B / A → T
10 20 50 100 200 300
Valve pressure differential in bar →

Pressure/signal characteristic curve, pS = 100 bar – spool symbol V
100
80
60
in % → 40
20
DpL
pS
–5 –3 –1 1 3 5
– 20
←
– 40

– 60
– 80
– 100
UE
← in % →
UEN
Leakage flow with central spool position  – spool symbol V
2
Leakage flow in l/min →
0 50 100 150 200 210 250 300 315

Operating pressure in bar →
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
30 1 Dp = 10 bar constant
P → A / B → T 5
2 Dp = 20 bar constant
Flow in l/min →
20 or
P → B / A → T 3
10
0 10 20 30 40 50 60 70 80 90 100 V-spool
15 20 30 40 50 60 70 80 90 100 E- and W-spool

Command value in % →

60 5
P → A / B → T
50 or
P → B / A → T
40
Flow in l/min →
30
2
20
1
10
0 10 20 30 40 50 60 70 80 90 100 V-spool
15 20 30 40 50 60 70 80 90 100 E- and W-spool


120
110 P → A / B → T 5 Permissible max. flow
100 or Note:
90 P → B / A → T Observe flow/load function
80 on page 8!
4
Flow in l/min →
70
60 3
40
30 1 4 Dp = 50 bar constant
10
0 10 20 30 40 50 60 70 80 90 100 V-spool
15 20 30 40 50 60 70 80 90 100 E- and W-spool


Transfer function with stepped electrical input signals
4/3 valve variant, spool symbol V Signal change in % →
100 0 – 100 – 0
75 0 – 75 – 0
Stroke in % →
50 0 – 50 – 0
25 0 – 25 – 0
60 0 0 20 40 20 40 60
Time in ms →
Frequency response characteristic curves – spool symbol V
5 –315
0 –270
–3
–5 –225
–10 –180
–15 –135
–20 –90
Signal ±10 %
–25 –45
Signal ±25 %
–30 0 Signal ±100 %
1 10 20 30 50 100 200
Frequency in Hz →
Flow load function at max. valve aperture – spool symbol V
400
75 Permissible
180
max. flow
Flow in l/min →
100 50
25
50
25
P → A / B → T
or
P → B / A → T
10
10 20 50 100 200 300

Pressure/signal characteristic curve, pS = 100 bar – spool symbol V
100
80
60
40
in % →
20
DpL
pS
–5 –3 –1 1 3 5
– 20
←
– 40

– 60
– 80
– 100
UE
← in % →
UEN
Leakage flow with central spool position – spool symbol V
2
Leakage flow in l/min →
0 50 100 150 200 210 250 300 315

Operating pressure in bar →
Characteristic curves of size10 (measured with HLP46, ϑoil = 40 °C ±5 °C, p = 100 bar)

80 5
P → A / B → T
or
P → B / A → T 4
Flow in l/min →
50
40
2
30
1
20
10
0 10 20 30 40 50 60 70 80 90 100 V-spool
10 20 60 3070 4080 5090 100 E- and W-spool

150 5
125 P → A / B → T 2 Dp = 20 bar constant

or 3 Dp = 30 bar constant
4
100 P → B / A → T 4 Dp = 50 bar constant
Flow in l/min →
75
2
50 1
25
0 10 20 30 40 50 60 70 80 90 100 V-spool
10 20 30 40 50 60 70 80 90 100 E- and W-spool

300
5 Permissible max. flow
275 Note:
250 P → A / B → T Observe flow/load function
225 or on page 11!
200 P → B / A → T
Flow in l/min →
180 4
175
3
2
75 1
50
25
0 10 20 30 40 50 60 70 80 90 100 V-spool
10 20 30 40 50 60 70 80 90 100 E- and W-spool

Unit dimensions of size 6 (dimensions in mm)
7 6 8
118,3
"a" "b"
47
42
23
13,6 55,6 45
139,4 123,8
18 152,4
5 2 4 1 3 9
20
Required surface quality 8,5 F1 F2

of valve mounting face T
0,01/100mm
48
Rzmax 4 A B
P
F4 F3
G
76
1 Valve housing Subplates to data sheet RE 45052

2 Proportional solenoid “a“ with inductive position trans- (separate order)
ducer G 341/01 (G1/4)
G 342/01 (G3/8)
3 Proportional solenoid “b“
G 502/01 (G1/2)
4 R-ring 9.81 x 1.5 x 1.78 (ports A, B, P, T)
5 Space required to remove mating connector Valve mounting screws (separate order)
6 Integrated digital electronics The following valve mounting screws are recommended:
7 Mating connector to DIN EN 175201-804, separate – 4 hexagon socket head cap screws
order, see page 17 ISO 4762 - M5 x 50 - 10.9-flZn-240h-L
(Friction coefficient μtotal = 0.09 to 0.14)
8 Nameplate
Tightening torque MT = 7 Nm ±10 %,
9 Machined valve mounting face, porting pattern to Material no. R913000064 (separate order)
ISO 4401-03-02-0-05 or
Deviating from standard: – 4 hexagon socket head cap screws ISO 4762 - M5 x 50 - 10.9
– Ports A, B, P, T Ø8 mm (Friction coefficient μtotal = 0.12 to 0.17)
– Bore G is not required, because valve is not pro- Tightening torque MT = 8.9 Nm ±10 %
vided with a pin
The tightening torques given are guidelines when screws of the
specified friction coefficient and a torque wrench are used (tol-
erance ±10 %).
Unit dimensions of size10 (dimensions in mm)
5 7 6 8
18
185,2
“a” “b”
72,5
40
30
19,1 73 69,3
185,9 180,3
2 4 1 3 9
23
Required surface quality
of valve mounting face
13
F1 P F2
0,01/100mm
A B
Rzmax 4
72
T T1
F4 F3
94
1 Valve housing Subplates to data sheet RE 45054

2 Proportional solenoid “a“ with inductive position trans- (separate order)
ducer G 66/01 (G3/8)
G 67/01 (G1/2)
3 Proportional solenoid “b“
G 534/01 (G3/4)
4 R-ring 13.0 x 1.6 x 2.0 (ports A, B, P, T, T1)
5 Space required to remove mating connector Valve mounting screws (separate order)
6 Integrated digital electronics The following valve mounting screws are recommended:
7 Mating connector to DIN EN 175201-804, separate – 4 hexagon socket head cap screws
order, see page 17 ISO 4762 - M6 x 40 - 10.9-flZn-240h-L
8 Nameplate
Tghtening torque MT = 12.5 Nm ±10 %,
9 Machined valve mounting face, porting pattern to Material no. R913000058 (separate order) or
ISO 4401-05-04-0-05 –4 hexagon socket head cap screws ISO 4762 - M6 x 40 - 10.9
Deviating from standard: (Friction coefficient μtotal = 0,12 to 0,17)
– Port T1 is provided additionally 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 (tol-
erance ±10 %).
The following is required for parameterization with a PC: CANopen PROFIBUS DP

Material no. R901071963 Material no. R901071962
2 Operator tool WIN-PED 6
Download at www.boschrexroth.de/IAC
3 Connection cable, 3 m D-Sub / M12, coding A D-Sub / M12, coding B
Material no. R900751271 Material no. R901078053
1
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
F
B
Ø27
C E
Ø6,5…11
D
Mating connector to DIN EN 175201-804

Separate order stating Material no. R900223890 (metal variant)
85 Ø8…Ø13,5
CAN bus (A-coding)

X2
Circular plug-in connector, ca. 56 3
to be wired by customer, 4
5-pin, M12
2 5
Ø19,6
Straight mating connector,

metal variant 1
Mat. no: R901076910

(cable diameter 6 to 8 mm)
X3
Circular plug-in connector, ca. 61 3
5-pin, M12
4 5
Ø19,6
Straight plug-in connector,

metal variant 1
Mat. no: R901076906

M12 cap
Dust protector Mat. no.: R901075564
(for pins only)
PROFIBUS (B-coding)

X2
ca. 61
Circular plug-in connector, 4
1
3
5-pin, M12 2
Ø19,6
Straight plug-in connector,

metal variant
Mat. no.: R901075545
X3
ca. 56
Circular plug-in connector,
3 4
to be wired by customer,
5-pin, M12 5
1
Ø19,6
2
Straight mating connector,
metal variant
Mat. no.: R901075550
M12 protective cap
(for mating connector Mat. no.: R901075563
only)
Product documentation for IFB-P
Technical data sheet for 4WREF, RE 29048 (this data sheet)
CAN bus protocol description RE 29015-01-Z

PROFIBUS protocol description RE 29015-02-Z

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.
Notes
Bosch Rexroth AG ©This document, as well as the data, specifications and other information
wear and aging.
4/3 proportional directional valve, RE 29050/01.08
Replaces: 07.05
1/28
direct operated, with pQ functionality

and field bus interface (IAC-P)
Type 4WREQ
Sizes 6 and 10
Component series 2X
Maximum flow 180 l/min
HAD 7099/03

Content Page – Direct operated proportional directional valve with integrated
Features 1 digital control electronics for the closed-loop control of pres-
sure, force and flow (Integrated Axis Controller IAC-P)
Ordering code 2
– Completely matched unit consisting of valve, pressure
Symbols 2
sensor(s) (optional), digital closed-loop control electronics and
Standard types 3 field bus interface
Structure, function, section 3 to 5 – Actuation by proportional solenoid with central thread and
Technical data 6 and 7 detachable coil
Closed-loop control electronics, – Position-controlled valve spool
identification and adjustment elements 8 – Integrated pressure sensor plate (optional)
Electrical connections and pinout 8 and 9 – 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 – Version for CAN bus with CANopen protocol DS 408 or
Characteristic curves 12 to 19 PROFIBUS-DP V0/V1
Unit dimensions 20 to 23 – Fast commissioning by means of PC and
Accessories 24 to 26 commissioning software WIN-PED 6
Engineering / maintenance notes / supplementary information 27
2/28 Bosch Rexroth AG Hydraulics 4WREQ RE 29050/01.08
Ordering code
4WRE Q 2X V 24 *
With integrated digital electron- Further details

ics and pQ functionality = Q in clear text
Size 6 =6 Sensor interface for external
Size 10 = 10 pressure sensor 4)
Spool symbols 2 = 4 to 20 mA
A B 3 = 0 to 10 V
4 = 0 to 5 V
a 0 b a 0 b 9 = 0.5 to 5 V
P T 0 = Without external
= Q5- sensor interface
Electronics interface 5)
=V A6 = ±10 VDC
F6 = 4 to 20 mA
Nominal flow 1) Bus interface
Size 6 C = CAN bus DS 408
8 l/min = 08 P = PROFIBUS-DP V0/V1
16 l/min = 16 Supply voltage
32 l/min = 32 24 = 24 VDC
Size 10
25 l/min = 25 Position of pressure sensors
50 l/min = 50 0 = External sensor
75 l/min = 75 Internal sensor in channel
A = A
Component series 20 to 29 = 2X
B = B
(20 to 29: unchanged installation and connection dimensions) C = A+B
FKM - rectangular rings suitable for mineral oils F = P+A+B
(HL, HLP) to DIN 51524 =V Application Ordering code
Pressure rating with internal sensors Q control F
100 bar 2) =4
2) p control only in A A
160 bar =5
250 bar 2) =8 p control only in B B
400 bar 3) =B p control in A + B or ∆p con- C
External sensor =0 trol
1) See flow characteristic curves starting on page 12. 5) With command value input “A6“ only sensor interfaces “3“,
2) The selected pressure rating limits the max. valve pressure. “4“ or “9“ are possible.
3) Attention: With command value input “F6“ only sensor interface “2“ is
Maximum valve pressure 315 bar
possible.
4) When internal pressure sensors are used, no external pres-
sure sensor may be connected.
Symbols
Type 4WREQ.Q5-... Type 4WREQ.V...
P P
A B A B
G G
a b a b
P T P T
RE 29050/01.08 4WREQ Hydraulics Bosch Rexroth AG 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
– Housing (1) and pressure sensor plate (12) with connection – Position transducer (7)
face – Integrated pressure sensors (10)
– Control spool (2) with compression springs (3 and 4) and – Integrated digital closed-loop control electronics IAC-P (11)
spring plates (8 and 9)
– Coils (5 and 6) and pole tubes (14 and 15) with central
thread Continued on page 4
X1 11 X2
X3
P A B T
7 5 14 3 10 8 2 9 12 1 4 15 6
Note:
Draining of the tank line must be prevented. If the installation situation allows, install a suitable pre-load valve.
Structure, function, section (valve with integrated sensors)

Continued from page 3
Functional description
– When solenoids (5 and 6) are de-energized, control spool The following additional functions are available:
(2) is brought by compression springs (3 and 4) between – Ramp generator
spring plates (8 and 9) to the central position (if V-spool is – Internal command value profile
used, without spring plates). With V-spools, the mechanical
– Enable function analog / digital
zero position is not identical with the hydraulic zero position.
– Fault output 24 V
– Depending on the valve type, the following functions can be
performed (in some cases, combinations are possible): PC program WIN-PED 6
• Open-loop flow control (Q) For performing engineering work and parameterizing IAC-P
• Closed-loop flow control (Q) valves, the user can utilize the commissioning software WIN-
PED 6.
• Closed-loop pressure control in A and/or B (p)
- Parameterization
• Closed-loop force control (p)
- Diagnosis
• Alternating closed-loop control of p/Q
- Comfortable data administration on a PC
– The command values can be fed forward alternatively via an
analog interface (X1) or via the field bus interface (X2, X3). System requirements
– The actual value signals are made available via an analog – IBM PC or compatible system
interface (X1) and can be read out additionally via the field – Windows 2000 or Windows XP
bus (X2, X3). – RAM (recommendation 256 MB)
– The controller parameters are adjusted via the field bus – 150 MB free hard disk space
– For safety reasons, separate supply voltage for bus/control- Note
ler and power part (output stage)
– The program “WIN-PED 6“ is not included in the scope of
The digital integrated control electronics allows the following supply. It can be downloaded free of charge on the Internet!
faults to be detected: (See page 24)
– 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)
Structure, function, section (valve for external sensor)
Structure
– 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
Structure, function, section (valve for external sensor)

Continued from page 4

Functional description – Watchdog

– When solenoids (5 and 6) are de-energized, control spool – Cable break of command value inputs (with current interface
(2) is brought by compression springs (3 and 4) between only)
spring plates (8 and 9) to the central position (if V-spool is
The following additional functions are available:
used, without spring plates). With V-spool, the mechanical
zero position is not identical with the hydraulic zero position. – Ramp generator
– Functions: – Internal command value profile
– Enable function analog / digital
• Open-loop flow control (Q)
– 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 For performing engineering work and parameterizing the IAC-P
analog interface (X1) or via the field bus interface (X2, X3). valves, the user can utilize the commissioning software WIN-
– The actual value signals are made available via an analog PED 6.
interface (X1) and can be read out additionally via the field - Parameterization
bus (X2, X3).
- Diagnosis
– The controller parameters are adjusted via the field bus
- Comfortable data administration on a PC
– For safety reasons, separate supply voltage for bus/control-
System requirements
ler and power part (output stage)
– IBM PC or compatible system
The digital integrated control electronics allow the following – Windows 2000 or Windows XP
faults to be detected:
– RAM (recommendation: 256 MB)
– Cable break of pressure sensor supply cable
(depending on pressure sensor interface) – 150 MB free hard disk space
– Undervoltage Note
– Cable break of position transducer (7) – The program “WIN-PED 6“ is not included in the scope of
– Communication error supply. It can be downloaded free of charge on the Internet!
(See page 24)
X1 12 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.
General Size 6 Size10

Installation position Optionally, preferably horizontal
Storage temperature range °C –20 … +80
Weight with sandwich plate (3 sensors) kg 3.6 8.5
Weight without sandwich plate kg 2.4 6.5
Hydraulic (measured with HLP46, ϑoil = 40 °C ± 5 °C)
Operating pressure 1) 100 bar bar up to 100
160 bar bar up to 160
Ports P, A, B with sensor
Port T with sensor
Nominal flow qV nom at ∆p = 10 bar l/min 8 25
See flow characteristic curves from page 18 on 16 50
32 75
Max. permissible flow l/min 80 180
Hydraulic fluid Mineral oil (HL, HLP) to DIN 51524,
further hydraulic fluids on request
Hydraulic fluid temperature range °C –20 … +70, preferably +40 … +50
Viscosity range mm2/s 20 … 380, preferably 30 … 46
Permissible max. degree of contamination of the hydraulic fluid -
cleanliness class to ISO 4406 (c) 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 %/10 K < 0.15
temperature and operating pressure %/100 bar < 0.1
Electrical
Lower limit value VDC 19.4
Max. permissible residual ripple content Vss 2
Current consumption I max A 2
Impulse current A 3
Command and Voltage "A6" UQ V ±10
actual value signals Up V 0…10

Current "F6" IQ and Ip mA 4 … 20
Converter resolution (command/actual value signals) Bit 10
Duty cycle 3) % 100
Max. coil temperature 4) °C up to 150
Type of protection of valve to EN 60529:1991+A1:2000 IP 65 with plug-in connectors mounted and locked
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 closed- Note!

loop pressure control depends on the accuracy class of the For details regarding environment simulation tests in the fields
sensor used. of EMC (electromagnetic compatibility), climate and mechani-
cal stress, see RE 29050-U (declaration on environmental
compatibility).
1) Operating pressure, due to valve and sensor

2) Thecleanliness 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) Applysupply voltage for the valve only when required for the
functional sequence of the machine.
4) Dueto the surface temperatures of solenoid coils, observe
European standards ISO 13732-1 and EN 982!
Closed-loop control electronics (IAC-P), identification and adjustment elements
1: + 24V DC (UB)
2: 0V (UB) Rexroth
3: enable input 24V DC P
4: command value (Q) 1)
5: reference analog G
A B
6: actual value (Q) 1)
)( )(
7: command value (p) 2)
8: actual value (p) 2)
9: control supply +24V

10: control supply 0V ∗R900975074∗ P T
11: error output 24V DC 4WREQ6....
PE: earth conductor 0000000 00
1)
±10V 2) 0... 10V 0000
A001
1 Material number 1 2 3 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 Pinout of interface A6 Pinout of interface F6
litz wire
color 1)
1 1 24 VDC (u(t) = 19.4 V … 35 V), Imax = 1.7 A (for output stage)
2 2 0 V load zero, reference for pins 1 and 9
3 white Enable input 9 ... 35 V enable ON
4 yellow ±10 V command value Q Ri > 50 kΩ 4...20 mA command value Q Ri = 100 Ω
5 green Reference for command values Q and P
6 violet ± 10 V actual value Q 4...20 mA actual value Q
(limit load 5 mA) (load resistance max. 300 Ω)
7 pink 0 … 10 V command value P Ri > 50 kΩ 4...20 mA command value P Ri = 100 Ω
8 red 0 … 10 V actual value P 4...20 mA actual value P
(limit load 5 mA) (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 4 5
10 6
with cable set (see Accessories) 3
9 11
2 7
1 8
Closed-loop control electronics (IAC-P), electrical connections and pinout
X2
3
Connector plug pinout for CAN bus “X2“/”X3“ (coding A), 2
M12, 5-pin, male/female
Baud rate kbit/s 20 to 1000 4 5
Pin Assignment
1 n. c.
CAN-specfic settings:
2 n. c.
The baud rate and identifier can be set via
3 CAN_GND the bus system or by means of the DIL X3
3
4 CAN_H switches.
5 CAN_L 4
2 5
X2
4
Connector plug pinout for PROFIBUS-DP, “X2“/”X3“ (coding B), 1
M12, 5-pin, male/female
Baud rate up to 12 MBaud 3 5
Pin Assignment
1 +5V
Setting by means of DIL switches
2 RxD/TxD-N (A-cable)
3 D GND X3
4 RxD/TxD-P (B-cable) 4
5 Shield 3
The +5-V voltage of the IAC-P is available for an external terminating resistor.
1 5
2
External pressure sensor connection “X4“ (coding A), M12, 5-pin, female
Pin Assignment Assignment X4

voltage interface current interface 1
1 Supply 24 VDC Supply 24 VDC 2
2 Signal (0...+5 V) Signal (4...20 mA)
4 5
3 Zero 0 V (GND) Zero 0 V (GND)
4 n. c. n. c. 3
5 n. c. n. c.
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.
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

Standard 20 kBaud 1 = standard or
0 0 0 0 0 0 0 0 00 1)
or reprogrammed reprogrammed
0 0 0 0 0 0 0 1 01
to to 20 kBaud 1 to 63
0 0 1 1 1 1 1 1 3F
1 = standard or
0 1 0 0 0 0 0 0 40 125 kBaud
reprogrammed
0 1 0 0 0 0 0 1 41
0 1 1 1 1 1 1 1 7F
1 = standard or
1 0 0 0 0 0 0 0 80 250 kBaud
reprogrammed
1 0 0 0 0 0 0 1 81
1 0 1 1 1 1 1 1 BF
1 = standard or
1 1 0 0 0 0 0 0 C0 500 kBaud
reprogrammed
1 1 0 0 0 0 0 1 C1
1 1 1 1 1 1 1 0 FE
Monitoring mode/
1 1 1 1 1 1 1 1 FF 250 kBaud programming mode
1 = fest
PROFIBUS-DP
B7 B6 B5 B4 B3 B2 B1 B0 HEX Address range

0 0 0 0 0 0 0 0 00 1) 125 = Standard or reprogrammed
0 0 0 0 0 0 0 1 01
1 to 126
to to
with parameter channel
0 1 1 1 1 1 1 0 7E
1 0 0 0 0 0 0 0 80
1 to 126
to to
without parameter channel
1 1 1 1 1 1 1 0 FE
1 1 1 1 1 1 1 1 FF Monitoring mode address 125
1) Factory setting
B7 B0 B7 B0
ON
ON
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Activation of the bus termination using the two lower switches
(with PROFIBUS-DP only):
ON
ON
2 1 2 1
Graphic on the left: Bus termination not activated
Graphic on the right: Bus termination activated
(both switches to “ON“)
Closed-loop control electronics (IAC-P), block circuit diagram
X2
External pressure
PROFIBUS-DP PROFIBUS
controller Pressure sensor plate: Pressure in P
X3
Alternatively Pressure sensor plate: Pressure in A
X2
Pressure sensor plate: Pressure in B
CAN bus Pressure sensor plate: Pressure in T
X3 2)
X4
X1 4
Command value Q I CAN A A A A
U A D D D D
D controller
Command value p 7 I D
A A
U D
Output stage B
Actual value Q 6 b
I PWM U
U I
8 Controller PWM
Actual value p I PID Output stage A
PWM
U U
Enable 3 Output I a
stage OFF
11 Act. positi-
Fault output on value Inductive
D Oscillator position
Microcontroller A
Reference for pins demodulator transducer
4; 7 5
=
Reference for pins EEPROM Flash ~
3; 6; 8; 11 10
GND Cable break
24V load supply
1
Output stage supply
24V signal supply
9 DC +Ui
–Ui
DC GND
GND 2
Protective earth
conductor 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 pres-
sure sensor via the 5-pin M12 mating connector X4
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
40
in %→
20
–30 –24 –18 –12
0
12 18 24 30
∆pL
pS
–20
←
–40
–60
–80
–100
UE
← in % →
UEN
Pressure/signal characteristic curve (V spool), ps  = 100 bar
100
80
60
40
in %→
20
–5 –3 –1 1 3 5
∆pL
pS
– 20
←
– 40
– 60
– 80
– 100
UE
← in % →
UEN
Flow, size 6 with Q5 spool Tolerance range of mechanical zero position
100
A→T B→T
80
60
Flow in % →
P→B P→A
40
20
0
–100 –80 –60 –40 –20 0 20 40 60 80 100
Flow, size 6 with V spool
100
90
80
70
60
Flow in % →
50
40
30
20
10
0 10 20 30 40 50 60 70 80 90 100
V08 spool
V16 spool
V32 spool
Flow/load function, size 6 with Q5 spool at max. valve aperture
200
Permissible
maximum flow
100
80
50 32
Flow in l/min →
P→A/B→T
16
or
P→B/A→T
08
10
5
10 20 50 100 200 300
Flow/load function, size 6 with V spool at max. valve aperture
Permissible
200
maximum flow
100
80 32
16
P→A/B→T
Flow in l/min →
08 or
P→B/A→T
10
1
10 20 50 100 200 300
Transient function, size 6 Signal change in %

100 0 - 100
75 0 - 75
Stroke in % →
50 0 - 50
25 0 - 25
0
0 10 20 30 0 10 20 30
Time in ms →
Frequency response, size 6 with Q5 spool, ps = 10 bar

10 – 360
0
– 270
–3
–5
–10 – 180
–15
–20 – 90
–25
–30
1 5 10 50 100 200
Frequency in Hz → Signal 50 ± 5 %
Signal 50 ± 12.5 %
Signal 50 ± 50 %
Frequency response, size 6 with V spool, ps = 10 bar
10 – 360
0 – 270
–3
–5
– 10 – 180
– 15
– 20 – 90
– 25
– 30 0
1 5 10 50 100 200
Frequency in Hz → Signal ± 10 %
Signal ± 25 %
Signal ± 1
00 %
Pressure/signal characteristic curve (Q5 spool), ps = 100 bar
Tolerance range of mechanical zero position

(-6 to +6 %)
100
80
60
40
in %→
20
–30 –24 –18 –12
0
∆pL
pS
12 18 24 30
←
–20
–40
–60
–80
–100
UE
← in % →
UEN
Pressure/signal characteristic curve (V spool), ps  = 100 bar
100
80
60
40
in %→
20
–5 –3 –1 1 3 5
∆pL
pS
– 20
←
– 40
– 60
– 80
– 100
UE
← in % →
UEN
Flow, size 10 with Q5 spool Tolerance range of mechanical zero position
100
A→T B→T
80
60
Flow in % →
40
P→B P→A
20
0
–100 –80 –60 –40 –20 0 20 40 60 80 100
Flow, size 10 with V spool
100
90
80
70
60
Flow in % →
50
40
30
20
10
0 10 20 30 40 50 60 70 80 90 100
V25 spool
V50 spool
V75 spool
Flow/load function, size 10 with Q5 spool at max. valve aperture
400
Permissible
maximum flow
180
75
50 25
100
Flow in l/min →
P→A/B→T
or
50 P→B/A→T
20
10
10 20 50 100 200 300
Flow/load function, size 10 with V spool at max. valve aperture
400
Permissible
maximum flow
75
180
100 50
Flow in l/min →
P→A/B→T
or
25
50 P→B/A→T
20
10
10 20 50 100 200 300
Transient function, size 10 Signal change in %

100 0 - 100
75 0 - 75
Stroke in % →
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
10 – 360
0 – 270
–3
Phase angle in °
–5
– 10 – 180
– 15
– 20 – 90
– 25
– 30 0
1 5 10 50 100 200
Frequency in Hz → Signal 50 ± 5 %
Signal 50 ± 12.5 %
Signal 50 ± 50 %
Frequency response, size 10 with V spool, ps = 10 bar
10 – 360
0 – 270
–3
–5
– 10 – 180
– 15
– 20 – 90
– 25
– 30 0
1 5 10 50 100 200
Frequency in Hz → Signal ± 10 %
Signal ± 25 %
Signal ± 1
00%
Unit dimensions size 6 (dimensions in mm)
Type 4WREQ with integrated pressure sensors

7 6 8
158,8
"a" "b"
47
23
82,5
40,5
19,5 55,5 45
88,5 123,8
140
18 152,4
5 9 2 4 1 3 10
15
0,01/100
8,5
F1 F2
T
Rzmax 4
47
Required surface quality of A B

valve mounting face P
F4 F3
1 Valve housing G
2 Proportional solenoid "a" with inductive position transducer
3 Proportional solenoid "b" 72
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
Subplates according to data sheet RE 45052 and valve
7 Mating connector to DIN EN 175201-804; mounting screws must be ordered separately.
separate order, see page 25
8 Nameplate G342/01 (G3/8)
9 Integrated pressure transducers G502/01 (G1/2)
10 Machined valve mounting face, Valve mounting screws:
porting pattern to ISO 4401-03-02-0-05 4 hexagon socket head cap screws
Deviating from standard: ISO 4762-M5x90-10.9-flZn-240h-L
– Ports P, A, B, T Ø8 mm (Friction coefficient μtotal : 0.09-0.14 to VDA 235-101)
– Bore G is not required, since the valve is not provided tightening torque MT = 8.9 Nm ± 10 %
with a pin. Material no. R913000222
Type 4WREQ for external pressure sensor

7 6 8
118,3
"a" "b"
47
42
23
13,6 55,6 45
139,4 123,8
18 152,4
5 2 4 1 3 9
15
8,5
F1 F2
0,01/100 T
Rzmax 4
47
A B
Required surface quality of P
F4 F3
valve mounting face G
72
1 Valve housing Subplates according to data sheet RE 45052 and valve

2 Proportional solenoid "a" with inductive position transducer mounting screws must be ordered separately.
3 Proportional solenoid "b" Subplates: G341/01 (G1/4)
G342/01 (G3/8)
4 R-ring 9.81 x 1.5 x 1.78 (ports P, A, B, T)
G502/01 (G1/2)
5 Space required to remove mating connector
Valve mounting screws:
6 Integrated digital closed-loop control electronics
– 4 hexagon socket head cap screws
7 Mating connector to DIN EN 175201-804; ISO 4762-M5x50-10.9-flZn-240h-L
separate order, see page 25 (Friction coefficient μtotal = 0.09 to 0.14)
8 Nameplate tightening torque MT = 7 Nm ± 10 %,
9 Machined valve mounting face, Material no. R913000064
porting pattern to ISO 4401-03-02-0-05 or
Deviating from standard: – 4 hexagon socket head cap screws
– Ports P, A, B, T Ø8 mm ISO 4762-M5x50-10.9
– Bore G is not required, since the valve is not provided (Friction coefficient μtotal = 0.12 to 0.17)
with a pin. tightening torque MT = 8.9 Nm ± 10 %
Type 4WREQ with integrated pressure sensors
6 5 7
185,2
"a" "b"
72,5
40
30
40,5
24 73 69,3
93 180,3
185,9
9
8 2 4 1 3
23
13
0,01/100 F1 P F2
Rzmax 4 A B
72
T T1
Required surface quality of
valve mounting face
F4 F3
100

mounting screws must be ordered separately.
3 Proportional solenoid "b"
G67/01 (G1/2)
4 R-ring 13.0 x 1.6 x 2.0 (ports P, A, B, T1, T2) G534/01 (G3/4)
5 Integrated digital closed-loop control electronics Valve mounting screws:
6 Mating connector to DIN EN 175201-804; – 4 hexagon socket head cap screws
separate order, see page 25 ISO 4762-M6x80-10.9-flZn-240h-L
7 Nameplate (Friction coefficient μtotal = 0.09 to 0.14)
8 Integrated pressure transducers tightening torque MT = 12.5 Nm ± 10 %,
Material no. R913000512 (separate order)
9 Machined valve mounting face,
porting pattern to ISO 4401-05-04-0-05 or
ISO 4762-M6x80-10.9
tightening torque MT = 15.5 Nm ± 10 %
Type 4WREQ for external pressure sensor
6 5 7
144,7
"a" "b"
72,5
40
30
19,1 73 69,3
185,9 180,3
2 4 1 3 8
20
13
0,01/100 F1 P F2
Rzmax 4 A B
72
T T1
Required surface quality
of valve mounting face
F4 F3
94

mounting screws must be ordered separately.
3 Proportional solenoid "b"
G67/01 (G1/2)
4 R-ring 13.0 x 1.6 x 2.0 (ports A, B, P, T, T1) G534/01 (G3/4)
5 Integrated digital closed-loop control electronics Valve mounting screws:
6 Mating connector to DIN EN 175201-804; – 4 hexagon socket head cap screws
separate order, see page 25 ISO4762-M6x40-10.9-flZn-240h-L
7 Nameplate (Friction coefficient μtotal = 0.09 to 0.14)
8 Machined valve mounting face, tightening torque MT = 12.5 Nm ± 10 %,
porting pattern to ISO 4401-05-04-0-05 Material no. R913000058 (separate order)
or
ISO 4762-M6x40-10.9
tightening torque MT = 15.5 Nm ± 10 %
The following is required for parameteriza- CANopen PROFIBUS-DP

tion by means of a PC:
Mat. no. R901071963 Mat. no. R901071962
2 Commissioning software WIN-PED 6
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
1
Accessories, connection X1 (not included in the scope of supply)
Mating connector für X1

Mating connector to DIN EN 175201 - 804 • Mating connector without cable (kit) Material no. R900884671
(11-pin + PE), plastic variant • Mating connector with cable set 2 x 5 m 12-pin Material no. R900032356
• Mating connector with cable set 2 x 20 m 12-pin Material no. R900860399
5 4
6 3
10
33
7 11 9 2
8 1
90
Accessories, sensor connection (not included in the scope of supply)

X4 (analog sen- ca. 61
sor)
Plug-in connector, 3
5-pin, M12, male, 2
Ø19,6
A coding,
straight connec- 4 5
tor, metal variant 1
Mat. no.: R901075542

(Cable diameter 4 to 6 mm)
Accessories, CAN bus (A coding) (not included in the scope of supply)

X2 ca. 56
Circular plug-in 1
connector,
2
to be wired by
Ø19,6
user, 5-pin, M12 4 5

Straight mating 3
connector, metal
variant. Mat. no.: R901076910
X3 ca. 61
Circular plug-in 3
connector, 2
to be wired by
4 5
Ø19,6
user, 5-pin, M12

1
Straight plug-in
connector, metal
M12 cap
Dust protector for
plugs only Mat. no.: R901075564
Accessories, PROFIBUS (B coding) (not included in the scope of supply)

X2 ca. 61
Circular plug-in
4
connector, 1
to be wired by 5
3
Ø19,6
user, 5-pin, M12 2
Straight plug-in
connector, metal
variant.
Mat. no.: R901075545
X3 ca. 56
Circular plug-in
connector, 3 4
to be wired by 5
Ø19,6
1
user, 5-pin, M12 2
Straight mating
connector, metal
M12 protective
cap (for mating Mat. no.: R901075563
connector only)
Product documentation for IAC-P
Product information RE 29015-P
Technical data sheet for 4WREQ, RE 29050 (this data sheet)
CAN bus protocol description RE 29015-01-Z

Profibus protocol description RE 29015-02-Z

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-rel-
evant machine functions! (See also European standard “safety requirements for fluid power systems and components - hydrau-
lics “, EN 982.)
– If electromagnetic interference is to be expected, take suitable measures to safeguard the function (depending on application,
e.g. shield, filter)!
Notes
wear and aging.
High-response valve with integrated RE 29191/09.10
Replaces: 06.05
1/22
digital axis controller (IAC-R) and

field bus interface
Type 4WRPNH.../24C...
Type 4WRPNH.../24P...
Size 6 and 10
Component series 2X
Maximum flow 100 l/min (Δp = 70 bar)
H7314

Content Page – Direct operated high-response valves size 6 and size 10 with
Features 1 control spool and sleeve in servo quality
Ordering code 2 – Single-side operated, 4/4 fail-safe position in deactivated
state
Standard types 3
– Integrated digital axis control functionality (IAC-R) for:
Symbols 4
• Flow control
Function, section 5 and 6 • Position control
Technical data 7 and 8 • Pressure control
Block diagram/controller functionality 9 • p/Q function
• Substitutional position/pressure and position/
Electrical connections, assignment 10 and 11
force control
Characteristic curves size 6 12 and 13 • NC functionality (stand-alone operation possible)
Characteristic curves size 10 14 and 15 – Analog and digital interfaces for command and actual values
Unit dimensions size 6 16 • 4 x analog sensors (+/–10 V or 4..20 mA) or
Unit dimensions size 10 17 • 1 x length measurement system (1Vss or SSI) and
2 analog sensors
Accessories 18 to 20
– Command value provision/actual value response analog
Project Planning / maintenance Instructions /
(current or voltage) or via field bus
additional Information 21
– 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 *
with integrated digital Further details in

axis controller and the plain text
NC functionality =N Sensor interfaces 4)
Control spools / sleeve =H A= X4, M12-5, ±10 V
X7, M12-5, ±10 V
Size 6 =6
B= X4, M12-5, ±10 V
Size 10 = 10
X7, M23-12, SSI 5)
Spool symbols C= X4, M12-5, ±10 V
4/4-directional design X7, M23-12, 1 Vss 6)
AB
G = X4, M12-5, 4...20 mA
a 0 b X7, M12-5, 4...20 mA
PT H = X4, M12-5, 4...20 mA
X7, M23-12, SSI 5)
= C3, C5
)( )( )( )( )(
)( )( )(
)( )( )( )(
Command value inputs

)(
)(
)( )(
)( )(
)( )(
)( )(
)( )( = C4, C1 A6 = ±10 VDC
F6 = 4...20 mA
)(
)(
)( )(
)( )(
)( )(
)( )(
)( )( =C Field bus interface
C= CANopen 7)
With symbols C5 and C1: P= Profibus DP V0/V1
P → A: qv B → T: qv/2 24 = Supply voltage 24 V
P → B: qv/2 A → T: qv
Seal material
Mounting side of the inductive position transducer M= NBR seals
AB suitable for mineral oils
(HL; HLP) according to DIN 51524
G
a 0 b b (standard) =B
PT 2X = Component series 20 to 29
(20 to 29: Identical installation
Rated flow at 70 bar valve pressure differential and connection dimensions)
(35 bar / control edge)
Size 6
2 l/min = 02
4 l/min = 04
12 l/min 8) = 12
15 l/min 1) = 15
24 l/min 8) = 24 1) Only in connection with flow characteristics "P"
25 l/min 1) = 25 2) qv 2:1 only with rated flow = 40 l/min
40 l/min 2) = 40 3) Inflection 60 % at size 6 with rated flow "15" and
Size 10
"25", otherwise inflection 40 %
50 l/min = 50
4) For sensor interfaces "A", "B" or "C" only command
100 l/min = 100
value input "A6" is possible.
Flow characteristics
For sensor interface "G" and "H" only command
Linear =L
value input "F6" is possible.
Inflected characteristic curve 3) =P
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-syn-
chronized PROFIBUS DP/V2 (PROFIdrive profile) can be seen on data sheet 29291.
RE 29191/09.10 4WRPNH Hydraulics Bosch Rexroth AG 3/22
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
Symbols
Size 6
A B
G p: Inflection 60 % p: Inflection 40 %
a 0 b b Linear [qn 15.25 l/min] [qn 40 l/min]
P T
C3, C5
Q Q
C4, C1
C3, C5, C4, C1
C C3, C5, C4, C1

Standard = 1:1, from qn = 40 l/min also 2:1
Size 10
A B
G
a 0 b b Linear p: Inflection 40 %
P T
C3, C5
C4, C1
C3, C5, C4, C1
C C3, C5, C4, C1

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)
High-response valve with integrated

axis controller with
analog interfaces (X1, X4, X7)
X1
X3
X7 X4
High-response valve with integrated

axis controller with
analog interfaces (X1, X4)
and digital X1
sensor interface (X7)
X3
X7 X4
1
Function, section
Functional description
The digital integrated control electronics enables the follow-
The IAC-R valve (Integrated Axis Controller on the basis of ing fault detection:
high-response valves) is a digital high-response valve with
– Cable break sensors
integrated axis controller with the following functionalities:
– Undervoltage
– Flow control
– Temperature of the integrated electronics
– Position control
– Communication errors
– Pressure control
– Watchdog
– p/Q function
– Substitutional position/pressure and position/
force control
– NC functionality The following additional functions are available:
– Ramp generator
– The command value can alternatively be provided via an – Internal command value profile
analog interface (X1) or via the field bus interface (X3)
– Release function analog/digital
– The actual value signals are provided via an analog interface
– Error output 24 V (e.g. as switching signal to PLC/logic and
(X1) and can additionally be read out via the field bus (X3).
further valves), max. 1.8 A
– The controller parameters are set via the field bus.
– Control output adjustment
– Separate supply voltage for bus/controller and power part
• Deadband compensation
(output stage) for safety reasons
• Zero point correction
• Valve inflection compensation
PC program WinHPT • Friction compensation
• Direction-dependent gain
To implement the project planning task and to parameterize
the IAC-R valves, the user may use the commissioning soft-
ware WinHPT (see accessories).
– Parameterization
– Programming of NC functionality
– Diagnosis
– Comfortable data management on a PC
– PC operating systems: Windows 2000 or Windows XP
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
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) l/min 2 4 12 15 24/25 40
Max. operating pressure Ports P, A, B bar 315
Port T bar 250
Limitation of use with regard Spool symbols C3, C5 bar 315 315 315 315 315 160
to the transition to failsafe
Spool symbols C1, C4 bar 315 315 315 280 250 100
Leakage oil at Linear characteristic curve L cm3/min < 150 < 180 < 300 - < 500 < 900
100 bar Inflected characteristic curve P cm3/min - - - < 180 < 300 < 450
hydraulic, size 10
Rated flow at Δp = 35 bar per edge 2) l/min 50 50 100 100
(1:1) (2:1) (1:1) (2:1)
Max. operating pressure Ports P, A, B bar 315
Port T bar 250
Limitation of use with regard Spool symbols C3, C5 315 315 160 160
to the transition to failsafe
Spool symbols C1, C4 250 250 100 100
Leakage oil at Linear characteristic curve L cm3/min < 1200 < 1200 < 1500 < 1500
100 bar 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.

Technical Data (For applications outside these parameters, please consult us!)
electric
Relative duty cycle % 100 (continuous operation)
Protection class according to EN 60529 IP 65 with mounted and locked plug-in connectors
Supply Nominal voltage VDC 24
voltage Lower limit value VDC 21
Max admissible residual ripple Vss 2 (at supply voltage of 23 V … 34 V)
Power consumption 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
2)
Δpx
1) The cleanliness classes specified for the components must Flow at different Δp: qx = qnom •
35
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.
Block diagram/controller functionality
PROFIBUS DP/ 1) 1)
X3 1)
CAN bus X4
Profibus controller /
CANopen controller
X7 1)
X1 4
Command value U(I) 1) A A A A A
U D D D D D
A B
P T
Command value 7 U(I) 1)
A
U D
a
Actual value 6 U(I) 1)
0
U PWM Output
stage
b
8 U(I) 1) Controller
Actual value PWM functionality PWM U
G
U PID
block I
b
Enable 3
Output
stage off
Switching output 11
D Actual
Microcontroller A value Oscillator
Reference for demodulator
command values 5 position
=
1 EEPROM Flash ~
24 V (load)
Supply for output stage and switching output
0 V (control voltage)
for pins 3, 6, 8, 9 10
GND
24 V (control voltage) 9 DC
DC GNDL
0 V (load) 2
Protective earthing
conductor PE
1) According to ordering code
Controller functionality block
Analog signals (volt- NC functionality

age/current) or digital Command variable
signals (CANopen or generator
Actuating variable
Profibus DP) of the Q control
Command vari-
Q control
able of command
value System controller variants Actuating vari-
able adaptation
Actual value p/Q control Actuating
(processed) Position control variable
Substitutional control of the
Actual pressure value system
Actual value processing controller
Actual position value
These variables must be parameterized.

Electrical connections, assignment

Unit connector pin assignment X1, 11-pole + PE according to EN 175201-804
Pin Core Assignment of interface A6 Assignment of interface F6
marking 1)
1 1 24 VDC (supply for output stage and power switching signal)
2 2 0V load zero (for output stage)
3 3 Release input 8.5 … 24 VDC = function, Re ~10 kΩ
4 4 Command value ±10 V; Re ~130 kΩ 4 … 20 mA command value; Re = 200 Ω
or dig. Input (from PLC) 2) or dig. Input (from PLC) 2)
5 5 Reference for command values
6 6 ±10 V actual value 4 … 20 mA actual value, load resistance ~330 Ω
or dig. Output (to PLC) 2) or dig. Output (to PLC) 2)
7 7 Command value ±10 V; Re ~130 kΩ 4 … 20 mA command value; Re = 200 Ω
or dig. Input (from PLC) 2) or dig. Input (from PLC) 2)
8 8 ±10 V actual value 4 … 20 mA actual value, load resistance ~330 Ω
or dig. Output (to PLC) 2) or dig. Output (to PLC) 2)
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)
1) Core marking of the connection lines for X1

line socket with cable set (see accessories) 4 5
2) 3 10 6
Selection via commissioning software
9 11
2 7
1 8
Unit connector pin assignment for CAN bus "X3" (code A), M12, 5-pole, pins
Pin Assignment External screen on both sides of the metallic

housing of the plug-in connection. 3
1 n.c.
Internal screens are not required. 2
2 n.c.
Transmission rate kbit/s 20 to 1000 4 5
3 CAN_GND
Bus address 1 to 127
4 CAN_H 1
5 CAN_L
Unit connector pin assignment for Profibus DP "X3" (code B), M12, 5-pole, socket
Pin Assignment Transmission rate up to 12 MBaud

1 VP
1
2 RxD/TxD-N (A line)
3 D GND 3 5
4 RxD/TxD-P (B line) 2
5 Shield
The galvanically separated voltage +5 V (pin 1 - VP) at the socket allows for passive termination of the profibus.
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
1 Supply 24 VDC Supply 24 VDC
2
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 5
4 Signal 1 (X4) / 2 (X7), (–10 … +10 V) Signal 1 (X4) / 2 (X7), (4 … 20 mA) 3
5 Shield Shield
1) 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

9 8
1 B 0V 1
2 10 12 7
2 Sense +5 V 1) Data
3 R Clock 3 11 6
4 R n.c.
4 5
5 A n.c.
6 A n.c.
7 n.c. n.c.
8 B n.c.
9 n.c. 24 V
10 0V 1) Data
11 Sense 0 V 1) Clock
12 +5 V 1) 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 transduc-
er 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.
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 2 3 4 Command value [%]

–20
–40
–60
–80
–100
ΔpB→A [%pP]
Bode diagram
A
⎯ [dB]
E
2
0
U E ±5
–2
UE±
ϕ [°]
–4
100
–6
%
–180 Amplitude
–8 –160
–10 –140 Phase
%
0%
–120
E 5
U ±
±10
–100
E
U
–80
–60
–40
–20
0
1 10 20 40 60 80 100 200 300
f [Hz]
Flow - signal function

L: Linear
Q [%]
100 qvA: qvB = 1:1
80
60 B-T q : q = 2:1
vA vB
40
20
–100 –80 –60 –40 –20 Command
Command 20 40 60 80 100 value [%]
value [%] –20
P-B
–40
–60
–80
–100
Q [%]
P: Inflection 60 % P: Inflection 40 %
Q [%] Q [%]
100 100 qvA: qvB = 1:1
80 80
60 60
B-T q : q = 2:1
40 vA vB
40
20 20
–100–80–60–40 –20 Command –100 –80 –60 –40 –20 Command
Command 20 40 60 80 100 value [%] Command 20 40 60 80 100 value [%]
value [%] –20 value [%] –20
P-B
–40 –40
–60 –60
–80 –80
–100 –100
Q [%] Q [%]
Fail-safe position
A B Leakage oil at 100 bar P→A 50 cm3/min

G P→B 70 cm3/min
b Flow at ∆p = 35 bar A→T 10 ... 20 l/min
P T B→T 7 ... 20 l/min

G P→B 70 cm3/min
b A→T 70 cm3/min
P T B→T 50 cm3/min
Fail-safe p = 0 bar => 7 ms Enable "off" or internal shut-off in case of error
p = 100 bar => 10 ms UB ≤ 18 V or I ≤ 2 mA (at 4…20 mA signal)
Pressure gain
ΔpA→B [%pP]
100
80
60
40
20
Command value [%] Command value [%]
–4 –3 –2 –1 1 2 3 4
–20
–40
–60
–80
–100
ΔpB→A [%pP]
Bode diagram
A
⎯ [dB]
E
2
0
ϕ [°]
UE ±
–2
UE ± 5
90%
–4 –200
%
–6 –180 Amplitude
–8 –160
5%
–10 –140 Phase

UE ±
%
E 90
–120
U ±
–100
–80
–60
–40
–20
0
1 10 20 40 60 80 100 200 300
f [Hz]
Flow - signal function

L: Linear 1:1 L: Linear 2:1
Q [%] Q [%]
100 100 qvA: qvB = 1:1
P-A
80 80
60 60 B-T qvA: qvB = 2:1
40 40
20 20
–100 –80–60 –40–20 –100 –80–60 –40–20
Command Command
value [%] –20 value [%] –20
–40 P-B –40
–60 –60
A-T
–80 –80
–100 –100
Q [%] Q [%]
P: Inflection 40 % 1:1 P: Inflection 40 % 2:1
Q [%] Q [%]
100 100 qvA: qvB = 1:1
80 80 P-A
60 60 B-T qvA: qvB = 2:1
40 40
20 20
–100 –80 –60 –40–20 Command –100 –80 –60 –40 –20 Command
value [%] –20 value [%] –20
P-B
–40 –40
–60 A-T –60
–80 –80
–100 –100
Q [%] Q [%]
Fail-safe position

G P→B 70 cm3/min
b Flow at ∆p = 35 bar A→T 10 ... 20 l/min
P T qn = 50/100 l/min B→T 7 ... 20 l/min

G P→B 70 cm3/min
b A→T 70 cm3/min
P T B→T 50 cm3/min
Fail-safe p = 0 bar => 12 ms Enable "off" or internal shut-off in case of error
p = 100 bar => 16 ms UB ≤ 18 V or I ≤ 2 mA (at 4…20 mA signal)
ca. 130 mm
ca. 150 mm
77
132
55
49
22
24 175
5 1 3 2
45
46
14 6
F1 F2 0,01/100
T
Rzmax 4
8,5
48
A B
P
F4 F3 Required surface quality of the
G valve mounting face
68,5
1 Valve housing Valve mounting screws

2 Control solenoid with position transducer (not included in scope of delivery)
4 units of hexagon socket head cap screws according to
3 O-ring 9.25 x 1.78 (ports P, A, B, T) ISO4762-M5x30-10.9-N67F 821 70
4 Integrated digital control electronics (galvanized according to Bosch standard N67F 821 70)
5 Name plate MA = 6+2 Nm
6 Machined valve mounting face, porting pattern Mat. no. 2910151166

according to ISO 4401-03-02-0-05
ca. 130 mm
ca. 150 mm
77
155
10
81
68
30
35 207
5 1 3 2
60
70
243
32 50,8±0,2
6 0,01/100
32,5±0,2 21
F1 P F2
Rzmax 4
A B
73
T T1
Required surface quality of the
valve mounting face
F4 F3
104,5
1 Valve housing Valve mounting screws

2 Control solenoid with position transducer (not included in scope of delivery)
4 units of hexagon socket head cap screws according to
3 O-ring 12.0 x 2.0 (ports P, A, B, T, T1) ISO4762-M6x40-10.9-N67F 821 70
4 Integrated digital control electronics (galvanized according to Bosch standard N67F 821 70)
5 Name plate MA = 11+3 Nm
6 Machined valve mounting face, porting pattern Mat. no. 2910151209
according to ISO 4401-05-04-0-05
Deviating from the standard:
– Port T1 is provided additionally
Accessories for parameterization (not included in scope of delivery)
The following is required for the CANopen Profibus DP

parameterization with PC:
Mat. no. R901071963 Mat. no. R901071962
2 Start-up software 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
1
Accessories, port X1 (not included in scope of delivery)
Mating connector for X1

Mating connector according to • Mating connector (construction set) for
Material no. R901268000
EN 175201-804 a cable diameter of 12-15 mm
(12-pole, metal design) • Mating connector with 5 m cable,
12 x 0.75 mm2 with cable shield, Material no. R901272854
assembled
• Mating connector with 20 m cable,
12 x 0.75 mm2 with cable shield, Material no. R901272852
assembled
SW22
5 4
6 3
10
SW24
7 11 9 2
8 1
41 M26x1,5
91
Accessories, sensor connections (not included in scope of delivery)
Description View, dimensions Pole image, order details

X4, X7 (analog sensors)
ca. 61
Plug-in connector, 5-pole, 3
M12 x 1, pins, A coding, 2
metal design
Ø19,6
4 5
Mat. no.: R901075542

(cable diameter 4 … 6 mm)
X7 (digital sensors, 61,1
1 Vss and SSI)
8 9 1
Plug-in connector,
12-pole, M23, pins, sol- 7 12 10 2
dered joint, metal design
with cap nut 6 11 3
Ø26
5 4
Mat. no.: R901076284

(cable diameter up to 10.5 mm)
Accessories, CAN bus (A coding) (not included in scope of delivery)
Description View, Dimensions Pole image, order details

X3
ca. 56
Round plug-in connec- 1
tor, processible, 5-pole, 2
M12 x 1
Ø19,6 4
Straight mating connector 5
from metal. 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 Pole image, order details

X3
ca. 61
Round plug-in connec-
4
tor, processible, 5-pole, 1
M12 x 1 5
3
Ø19,6
2
Straight line coupling plug
from metal.
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

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)!
Notes
Bosch Rexroth AG © This document, as well as the data, specifications and other informa-
Hydraulics tion set forth in it, are the exclusive property of Bosch Rexroth AG. It
Zum Eisengießer 1 may not be reproduced or given to third parties without its consent.
Phone +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain applica-
Fax +49 (0) 93 52 / 18-23 58 tion can be derived from our information. The information given does not
www.boschrexroth.de must be remembered that our products are subject to a natural process
of wear and aging.
Notes
of wear and aging.
Notes
of wear and aging.
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RE 30050/03.04
Replaces: 11.02
Analog position controller

Type VT-MACAS
Series 1X
Type VT-MACAS
List of contents Features
Contents Page – Design: Module for snapping onto DIN rails

Features 1 – Actuation of valves with on-board electronics
Ordering data 2 – Enabling input
Preferred types 2 – Open-circuit detection for feedback signal cable
Front panel 2 – Short-circuit-proof interfaces
Block diagram 3 – Measurement taps on front panel
Technical data 4 – Deadband compensation can be deactivated
Additional information 5 – Position: PT1 control
Device dimensions 6 – 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
VT- M A C A S - - / /
Option
Hydraulic component No code
Axis control =A Version with
supply input
I= Version with
Type current input
Controller =C
Customer version
Actuation V0 = Catalogue version
Analog =A
Series
Function 1X = Series 10 to 19
Position control =S
Serial numbers for types

500 = Standard version without valve amplifier function
Preferred types (available at short notice)
Material no. Type VT-MACAS For valve types

0 811 405 139 VT-MACAS-500-10/V0 Valves with on-board electronics
0 811 405 140 VT-MACAS-500-10/V0/I 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 (86 x 110 x 95) mm/module

Fastening/connection DIN rail/connector + terminals
Temperature range 0 ... 70 °C; storage: –20 ... +70 °C
Power supply UB = 24 Vnom/batt.: 21 ... 40 V DC
(8), (9) Single-phase full wave: 21 ... 28 V DCeff
Current rating Max. 200 mA
Signal input VT-MACAS-500-10/V0 Uset: ±10 V, difference amplifier
(1), (2) Ri = 100 kΩ
VT-MACAS-500-10/V0/I Iset: 4 ... 20 mA Rsh = 200 Ω
Feedback signal VT-MACAS-500-10/V0 Ufeed: ±10 V, difference amplifier
(3), (4) Ri = 100 kΩ
VT-MACAS-500-10/V0/I Ifeed: 4 ... 20 mA Rsh = 200 Ω
Valve signal UV = ±10 V (max. 10 mA) or
(5), (6), (7) IV = 4 ... 20 mA (average 12 mA)
Deadband compensation Can be deactivated,
effective in a range of ± 4 %
Enable signal (10) 8.5 ... 40 V DC
Fault signal (11) No fault: 24 Vnom (UB) max. 50 mA
Fault: < 2 V
IN POS signal (12) IN POS: 24 Vnom (UB) max. 50 mA
Not IN POS: < 2 V
Ramp ranges I: 0.1 ... 1 s
II: 1 ... 10 s
Area ratio adjustment Min. 1:1; max. 1:4
AK:AR
Feedback signal adjustment Zero: –5 ... 10 %
Gain: 50 ... 110 %
Type of controller Position: PT1
Velocity: PI
Valve zero ±5%
Special features – Module can be switched from position to velocity control
– Position window can be switched over
– Measurement taps on front panel
– Short-circuit-proof interfaces
RE 30050/03.04 4/6 VT-MACAS

Additional information
Applications
This controller module enables simple position or velocity we were able to keep the cost of the drive low. A further
control actions to be effected, in combination with Bosch speciality of this module is that it can be switched over internally
Rexroth servo cylinders with analog position measurement (front panel) to velocity control, and there is a version for
systems (potentiometers). Since the signals are processed in an voltage interface and a version for current interface, related to
analog manner and the module is only equipped with the most the setpoints and feedback signals.
essential features required for performing a control action,
Position control
The setpoint and feedback signals of the position are compared are limited either by the available power or the system gain.
and the difference transmitted to the valve amplifier. In the event When a ramp function acts as an input value, the load is moved
of an abrupt change in the input signal, the system reacts with at a constant speed.
maximum dynamics. The times for accelerating or braking a load
Velocity control*
The setpoint and feedback signal of velocity are compared and When a ramp function acts as an input signal, progressive
the difference transmitted to the valve amplifier. Through the acceleration or deceleration with a constant value takes place.
process of integration, the signal is amplified to such an extent * Only possible with a speedometer.
that even the smallest error is eliminated.
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 The information contained herein is intended
to serve purely as a product description.
D-97813 Lohr am Main The information we have provided
Zum Eisengießer 1 D-97816 Lohr am Main cannot be used as evidence of a particular
Telefon 0 93 52/18-0 aspect or of suitability for a particular purpose.
Telefax 0 93 52/18-23 58 Telex 6 89 418-0 Please note that our products are subject
eMail documentation@boschrexroth.de to the natural processes of ageing and wear.
Internet www.boschrexroth.de
RE 30050/03.04 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

Contents 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
Front plate 2 – Valve position control with PID behavior
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
Block diagram daughter card 9 – Cable break detection for actual value cable and pres-
Mode setting 10 sure sensor
General notes 11 – Fast energization and fast deletion for short actuating times
Ideal development 12 – External controller shut-off
Adjustment protocol 13 – Suitable for pressure sensors (1...6 V, 0...10 V, 4...20 mA),
see data sheet 30271
Unit dimensions 14
Project planning / maintenance instructions /
additional information 14
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 A R A P 1 2X V0
Hydraulic component Option
(control) no code = High-response valve size 6/10
Axis control =A direct operated
Valve type 5/3V = p/Q valve size 10
High-response valve =R direct operated
2STV = High-response valve
Control pilot operated
Analog =A 3/2V = High-response valve pilot operated
Function Control line A → X
p/Q control =P Customer version
Output stages V0 = Catalog version
1 output stage =1 2X = Component series 20 to 29
(20 to 29: Unchanged technical data
and pin assignment)
Serial number for types
527 = 2.7 A solenoid
537 = 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 Enable Command value signal Q

ON
Qmax Pot Qmax
UB
LED red UB < UB min. Qmax TP Q Pressure controller Off
1
13 5 KP Hex KP
9
Regler LED
1 off
Zero point adjustment
13 5 KI Hex KI Cable break pressure sensor
9
ON LED
1
13 5 KD Hex KD
QA 9
Pressure controller effective
P Pot p gain
+ 5% – –
+ + Pnull Pot p zero
–UE +UE valve P TP p
TP 0 V Pressure sensor
Lvdt 0V
QB
LED yellow Cable break

+UB
z32 z2
+10 V/10 mA DC +UB 24V = Supply
Potentiometer supply +10 V
b32 z4
10 V/10 mA 10 V +
b12 + 15 V b4
Control zero + 10 V
b14 DC b2
+15 V
15 V z28 0 V Neutral point
On
8.5 V= b2 Power zero
+10 V z16 z28 Control zero
Enable 100 k
max 40 V= Safety logic
max 40 V red
green
RE 30058/06.12 VT-VARAP1-...-2X/...
+UB yellow
0811405152, 0811405153, 0811405154
24 V z22 24 V=
Error Lvdt.
0V max100 mA Zero point
adjustment
Block diagram with pin assignment
Differential amplifier +5 %
z20 +10 V b22
Command 0... + 10 V 100 k 3-1 3-5 ΔS
UE z30
value Q b20
0V 100 k Ref -0- b24
z18 2-2 b30
Test (p) 0...+10 V Qmax
p controller
b10 1-4 +UB
6...40 V
OFF b6
b8
+UB
z24 1-7 1 2 1 2 3 4
p controller is working
b18 1-6 3-2
Ref. 0 V pgain +15 V
3-3 Size 6
4...20 mA z14 2-4 –15 V Size 10
p sensor 3-4
D St.–0 V
b16 1-5 + I P
1...6 V/0...10 V
pzero
z12 2-1
Command 0...+10 V U
z10 2-3 1-1 s
value p 0V L –0 V
Cable
z6 1-2 break
Sensor +15 V
supply
b30 1-3
–15 V
Hydraulics Bosch Rexroth AG
3/14
+UB
z32
4/14
z2
+10 V/10 mA DC +UB 24V = Supply
Potentiometer supply +10 V
b32 z4
10 V/10 mA 10 V +
b12 + 15 V b4
0811405156
0811405155,
Control zero + 10 V
b14 DC b2
+15 V
15 V z28 0 V Neutral point
On b2 Power zero
8.5 V=
Enable +10 V z16 z28 Control zero
100 k
max 40 V= Safety logic red
max 40 V
green
+UB
+10 V b26
ΔS
Bosch Rexroth AG Hydraulics
24 V yellow z30
Error z22 24 V=
Zero point
Lvdt. Ref -0- b28
0V max100 mA
adjustment b30
Differential amplifier +5 %
z20 +10 V b22
Command 0...+10 V 100 k 3-1 3-5 ΔS
value Q UE z30
b20
0V 100 k Ref -0- b24
z18 2-2 b30
Test (p) 0...+10 V Qmax
b10 1-4 +UB
p controller 6...40 V
OFF b6
b8
+UB
z24 1-7 1 2 1 2 3 4 1 2 3 4
p controller is working
b18 1-6 3-2
Ref. 0 V +15 V
pgain 3-3 4WRL... or
4...20 mA z14 2-4 –15 V
p sensor 3-4 3WRCBH25...50
D St.–0 V
b16 1-5 + I P
1...6 V/0...10 V
pzero
z12 2-1 U
Command 0...+10 V s
z10 2-3 1-1
value p 0V L –0 V
Cable
z6 1-2 break U
Sensor +15 V s
supply b30 1-3
–15 V
VT-VARAP1-...-2X/... RE 30058/06.12
RE 30058/06.12 VT-VARAP1-...-2X/... Hydraulics Bosch Rexroth AG 5/14
Technical data (For applications outside these parameters, please consult us!)
Supply voltage Nominal 24 V =

UB at z2 – b2 Battery voltage 21...40 V,
Rectified alternating voltage Ueff = 21...28 V
(one-phase, full-wave rectifier)
Smoothing capacitor, separately Recommendation: Capacitor module VT 11110 (see data sheet 30750)
at z2 – b2 (only necessary if the ripple of UB > 10 %)
Valve solenoid, max. A/VA 2.7/40 (size 6) 3.7/60 (size 10)
Current consumption, max. 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
z20: 0...±10 V ｝ Differential amplifier
(Ri = 100 kΩ )
Input signal (command value p) z12: 0...10 V
z10: 0 V ｝ Differential amplifier
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
Error message
– Cable break actual value
– UB too low z22: Open collector output to +UB
– ±15 V stabilization Max. 100 mA; no error: +UB
Circuit board format mm (100 x 160 x approx. 35) / (W x L x H)
Europe format with front panel 7 TE
Plug-in connection Connector DIN 41612 – F32
Ambient temperature °C 0...+70
Storage temperature range °C –20...+70
Weight m 0.49 kg
Notice:
Power zero b2 and control zero b12 or b14 or z28 must be separately led to the central ground (neutral point).
Applications The combination of valve amplifier and p/Q controller

The p/Q closed-loop control amplifiers consist of a basic takes effect:
card with front plate containing the valve amplifier with posi- a) As long as pcommand < pactual as flow control,
tion control as well as an attached daughter card on which i.e. the pressure control does not take effect, yet.
the actual pressure control has been realized. b) With pcommand ≧ pactual as pressure control, i.e. the flow
These amplifiers are only supplied as complete combinations. is reduced until pactual = pcommand. The pressure control
In connection with the corresponding high-response valves works only with a positive command value voltage at z20.
(see table page 2) and pressure sensors (sensor sig- The command value Q corresponds to the spool path as
nal 1...6 V, 0...10 V or 4...20 mA), flows can be controlled long as the pressure control does not take effect, yet, i.e.
and pressures in closed control loops can be regulated. pcommand > pactual or if the pressure controller is switched off
The input variables are the pressure p and flow Q command (DIL 4 OFF). The command value Q may range between
values. Pressure and valve spool path are fed back as ac- UE = 0...±10 V. For the dynamic pressure control there
tual values. should, however, in addition to the command value p also
be a command value Q1 UE ≧ 2...+10 V.
Examples
Example 1
Pressure control in a cylinder chamber for achieving a con-
stant clamping force.
Command value p
+ Pressure controller
p
U
Actual value p
A B
G
P T
Command
value Q
Limiter
Basic card Daughter card

Example 2
Flow with load compensation controlled via pressure com-
pensator and the pressure regulated in the closed control
loop (pressure cut off).
Command value p
+ Pressure controller
p
U
Actual value p
A B
p controller OFF
G
P T
Command
value Q
Limiter
Pressure compensator
Function
The combination of basic card and daughter card is shown The control deviation is amplified by a PID controller and
in the block diagrams on page 3 and 4. Details of the daugh- reaches a limiter superimposing the command value Q with
ter card, i.e. the pressure control, result from a detailed the pressure controller signal if pcommand ≦ pactual.
block diagram on page 9. As long as pcommand > pactual or if the command value Q rang-
The command value p (z12) is specified by the user by es between 0…–10 V, the limiter and thus the pressure con-
a voltage 0...+10 V, e.g. by means of a potentiometer which trol do not take effect and there is simple flow control.
can be supplied from z32/b12 (z10 to 0 V). The characteristic of the PID controller and the D ele-
The actual value p is supplied by a pressure sensor. Option- ment can be roughly set by means of the DIL switch on the
ally, sensors with current signal interface 4…20 mA or volt- daughter card and finely by means of the HEXCODE switch
age signal interface 1…6 V and/or 0…10 V can be used. on the front plate. If the pressure is regulated, this condition
Zero point and sensitivity of the sensor can be set at the is displayed on the front plate (LED) and can be used for
front plate. Cable break of the pressure sensor is signalized switching purposes via an acknowledgement output (z24).
(LEDs flash) if the sensor is supplied at z6. However, the pressure control can also be switched off so
Command and actual value are compared in the summing that there is only flow control, independent of pactual.
point which is moreover affected by a differentiated actu-
al value.
Principle of the control loop Command value p
P element
+
Actual value p KP
D element
TV
TI
Pressure increase
I element
Command
Basic card
value Q
Limiter
Pressure sensor connection versions
Usup z6
Usup z6 Usup z6
P P P 0 V/ b12
0 V/ b18
Usig b16
Isig z14 Usig b16
I U U 0 Vsig b18
b18 b18
b12 b12
P1
(Q max )
Command value signal Q Limiter Command
3-1 value p/Q
from the basic card
P6 + 3-5 to the ba-
+ sic card
A
DIL5
Leakage oil TP1 Q
DIL4 0...+10 V
b10 1-4 Default
p controller OFF 6...40 V
* settings "I"
+15 V Pressure controller
z6 1-2 DIL3 OFF
Supply p sensor
1-7 z24 p controller
RE 30058/06.12 VT-VARAP1-...-2X/...
z8 1-3
Block diagram daughter card
–15 V is working
Error signal
b18 1-6
0V 100 k Controller active
DIL2
200 Ω
p sensor
z14 2-4
4...20 mA 100 k pgain
+
b16 1-5 DIL11-16
1...6 V/0...10 V 100 k DIL6-10 L –0 V
DIL1 +UB +15 V
– pzero –UB –15 V
+
+ + St – 0 V
TP2
TP3 (0 V)
z18 2-2 KD KI KP
p 0...+10 V
z10 2-3 S3 S2 S1
Command value signal p z12 2-1 + Command value
signal p
* Cable break p sensor
9/14
Mode setting (DIL switch, daughter card)
DIL 16...0
DIL Status Function

no.
0 – without function
1 ON Pressure sensor 1...6 V/0...10 V
OFF signal 4...20 mA
2 ON Pressure sensor pSYS ≙ ∼ pNOM3)
2)
OFF amplification pSYS ≙ ∼ 0.5 pNOM

3 ON Cable break On
OFF monitoring Off
pressure sensor
4 ON Pressure controller On
OFF Off
5 ON Valve output signal not inverted
OFF inverted
6 ON Pressure build-up normal
OFF reduced 1)
7 ON Pressure normal
OFF D reduction reduced 1)
8 ON Share high (9, 10 = OFF)
9 ON Share medium (8, 10 = OFF)
10 ON Share low (8, 9 = OFF)
11 ON Share = 0 (12 = OFF)
I
12 ON Share available (11 = OFF)
13 ON Reduced pressure Valve opening in
reduction case of pressure
reduction
< approx. 15 %
OFF P 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 = System pressure

3) pNOM = Nominal sensor pressure
General notes:
Setting during the commissioning is effected using potenti- Before the commissioning, the basic settings of the as-delivered
ometers and HEXCODE switches on the front plate as well state are to be checked.
as using DIL switches on the daughter card bottom side. In the card comparison, proceed in the order of the
Test points for voltage measurements as well as LED dis- points shown:
plays 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 D: Controller adjustment

front plate) The P, I and D shares of the closed-loop control ampli-
1) DIL 4 OFF (pressure controller OFF) fier are to be optimized according to the properties of the
2) Applying the voltage and pressure supply control distance, the disturbance variables and the static
and dynamic requirements on the control result.
3) Command value specification Q = 0 V
4) Use the "Zero"
potentiometer to bring the cylinder to a standstill 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
B: Pressure sensor comparison 4) DIL 6 and DIL 7 serve to compensate dynamic dif-
ferences in the pressure build-up and reduction in
1) Sensor type selection the system
DIL 1 ON ≙ UA = 1...6 V/0...10 V DIL 6 ON = Normal application
OFF ≙ UA = 4...20 mA OFF = Special application
2) Sensor amplification selection DIL 7 ON = Normal application
DIL 2 ON if pSYS ~ pNOM OFF = Special application
OFF if 0.5 · pNOM ≦ pSYS ≦ pNOM 5) DIL 13 – reduces the pressure reduction
3) Hydraulic supply OFF by means of a valve opening
< approx. 15 %
4) Zero point calibration with potentiometer ON = Special application
"PZero" (at TP " " = 0 V) OFF = Normal application
5) Hydraulic supply ON – max. system pressure 6) Aim of the controller optimization
6) Sensitivity adjustment with potentiometer " P" An optimum between change over characteristic (over-
(at TP " P" = 10 V) shooting 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)
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
C: Comparison – command value Q
the I share reduces the static gain. With increasing static
1) Specification Qcommand = 10 V gain, the control deviation is reduced (d).
2) Limitation of the max. valve opening The D share can be used to influence the transition be-
(50...100 % opening) by potentiometer "Qmax". havior (minimization of the tendency to oscillate); thus,
Control of the voltage value at TP "Qmax": the command value is only reached after a longer transi-
10 V ≙ 100 % Valve opening (with Qcommand = 10 V) tion time (f).
5 V ≙ 50 % Valve opening (with Qcommand = 10 V)
Ideal development
U
psoll
pist
t
b Problem:
P share too small
U Solution:
➝ Rotate KP against 13 (fine adjustment)
psoll ➝ P gain >
pist DIL 14 ON
DIL 15 OFF
t
DIL 16 ON
c Problem:
P share too large
U Solution:
➝ Rotate KP against 0 (fine adjustment)
psoll
➝ use DIL 14 –16 to reduce the
P gain according to the table
pist
t
d Problem:
P share correct, control deviation too large
U pist Solution:
➝ Increase the I gain share
psoll ➝ DIL 11 ON = I share = 0
DIL 12 ON = I share connected
➝ Rotate KI against 13
e Problem:
Time constant of the I share too low
U Solution:
➝ Rotate KI against 13 until control deviation and vibration are perfect
psoll ➝ If KI = 13 is not sufficient, the P share must also be reduced
pist
t
f Problem:
D share too low
U Solution:
psoll
➝ Rotate KD against 13
➝ D share >
pist DIL 8 ON
t DIL 9 OFF
DIL 10 OFF
Adjustment protocol
Switches As-delivered state
Created by:
DIL 1 OFF
DIL 2 ON
Date:
DIL 3 ON
DIL 4 ON
DIL 5 OFF
DIL 6 OFF
DIL 7 OFF
DIL 8 OFF
DIL 9 OFF
DIL switch DIL 10 OFF
ON ON
ON DIL 11 OFF
OFF
5 4 3 2 1
DIL 12 OFF
DIL 13 OFF
HEXCODE switch DIL 14 OFF
1 DIL 15 ON
DIL 16 OFF
13 5
HEX KP 3
HEX KI 9
9
HEX KD 5
Unit dimensions (dimensions in mm)
35
Plug-in connector
DIN 41612 - F 32
100
24 V= Mains
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.
documentation@boschrexroth.de tion can be derived from our information. The information given does not
www.boschrexroth.de 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
of wear and aging.
Bosch Rexroth AG Hydraulics VT-VARAP1-...-2X/... RE 30058/06.12
Notes
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

Contents Page – Suitable for controlling high-response valves with in-
Features 1 stalled 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 – Suitable for pressure sensors (1...6 V, 0...10 V, 4...20 mA),
Examples 6
– Supply for pressure sensors
Functional presentation 7
– Cable break detection for pressure sensor
Special function 7
Setting instructions 8
Controller adjustment 9
Notice:
Ideal development 10
Adjustment table 11
Unit dimensions 12
2/12 Bosch Rexroth AG Hydraulics VT-VACAP-500-2X/V0/... RE 30134/06.12
VT V A C A P 500 2X V0
Hydraulic component Option
(control) no code = 1 channel
Axis control =A 2CH = 2 channels
Valve type Customer version
High-response valve =C V0 = Catalog version
Control 2X = Component series 20 to 29
Analog =A (20 to 29: Unchanged technical data
and pin assignment)
Function
p/Q control =P Serial number for types
500 = 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

Only for control cabinet installation!
Front plate
1 and 2 with 0811405157

1 only with 0811405158
1 2
Flow preselection Q max
Zero point flow
– – Q=0
+ +
Adjustment KP KP
Pressure controller off Regler
off
Adjustment KI KI
Controller is working ON
Adjustment KD KD
Amplification p signal +10 %/–20 % Pist
Pressure zero point ±10 %
– – 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
External p controller 6…40 V b10 "Controller off"

shut off
DIL4
0…10 V z12
P soll PID
0V z10 Tp4 Tp5
0…+10 V z20 S5/S6
0V
Qsoll
0V b20 Qmax b2
(D)
Q=0
Tp b8 UAll
Actual value pressure 0…10 V z18 (E)
monitor signal DIL2
4…20 mA z14 “ ON” DIL5 II
zero
+5 % U U
pist
p sensor 1...6 V/0...10 V b16 b32
24 V
0V b18 “ ON”
Signal Message
DIL1 pnull DIL3 A
External controller 24 V/20 mA z24 line M (no message
V Daughter > 8 V 20 mA)
enquiry
off "Controller off" card
24 V z2 +10 V
UB
z4 DC Basic card
+15 V
0V
0V b2 DC –15 V
z6
Supply p sensor 15 V/100 mA DIL0
6…40 V z30
External channel change
10 V z32 No
Potentiometer supply 1
6…40 V z28 "Controller off"
External p controller
shut off
DIL4
0…10 V b12
P soll PID
0V b14 Tp4 Tp5
0…+10 V z22 S5/S6
0V
Qsoll Qmax
0V b22 b4
(D)
Actual value pressure Tp Q=0 b8 UAI (E)
monitor signal (max. 1 mA) 0…10 V z16
DIL2
4…20 mA b24 “ ON” DIL5 II
zero
+5 % U U
pist
p sensor 1...6 V/0...10 V b26 b30
24 V
0V b28 “ ON”
Signal Message
DIL1 pnull DIL3 A
(no message
24 V/20 mA z26 line M
External controller V
> 8 V 20 mA)
enquiry off
"Controller off"
* Daughter card only attached with 2-channel variant


Current consumption, max. 0811405157 160 mA
0811405158 220 mA
Pressure sensor (1...6 V/0...10 V) b26 – Ref. b28 b16 – Ref.
Pressure sensor (4...20 mA) b24 – Ref. b28 b18z14 – Ref. b18
Pressure sensor supply – V z6 (+15 V)/b8 (0 V)
Pressure command value (0...10) V b12/b14 (0 V) z12/z10 (0 V)
External controller shut off z28: 6...40 V = b10: 6...40 V =
External controller enquiry z26: 24 V =, max. 20 mA z24: 24 V =, max. 20 mA

Monitor signal pactual z16: 0...10 V = z18: 0...10 V =
External channel change mode z30: 6...40 V =
Flow command value z22: 0...±10 V = z20: 0...±10 V =
b22: 0 V b22: 0 V
Potentiometer supply z32: +10 V, max. 10 mA
Output UAI; b4/b8 (0 V): 0...±10 V UAIl; b6/b8 (0 V): 0...±10 V
Load RL > 1 kΩ Load RL > 1 kΩ
Cable: Pressure sensor 4 x 0.5 mm2 (shielded)
Valve 5 x 0.5 mm2 (shielded)
PLC signals 0.5 mm2 (shielded)
LED displays/channel Pressure controller OFF
Controller is working
Cable break pressure transducer (both a.-m. LEDs are flashing)
Special features Cable break monitoring for pressure sensor
Test points for important characteristics
External pressure controller shut-off
External channel change mode
Different pressure sensors possible
Circuit board format mm (100 x 160 x approx. 35) / (W x L x H)
Europe format with front panel 7 TE
Weight m 0811405157 – 0.35 kg, 0811405158 – 0.44 kg
Connection scheme
Amplifier – Valve
Signal exchange with system control
24 V DC
0V
p/Q card Signal
1 channel
UB Pressure command value
z.B.
4/4 WV – NG10 Monitor signal pactual
p/Q control signal 5/3 WV – NG10
Controller enquiry
Reference – 0 V
3/2 WV (Cartr.) + Pilot
p 4/4 WV – NG6 Controller shut-off
U 4/3 WV + Pilot
Channel change mode
Pressure sensor connection: Example channel II
Usup z6
Usup z6 Usup z6
P P P 0 V/ b2
0 V/ b18
Usig b16
Isig z14 Usig b16
I U U 0 Vsig b8
b18 b18
b8 b8
Applications
The "1-channel p/Q control card" consists of the basic card The pressure command value can be specified by means of
in Europe format with DC/DC converter and front plate. With a potentiometer. The potentiometers can be supplied from
the "2-channel p/Q control card", this basic card contains a the card (z32/b12).
p/Q daughter card with identical circuit and a joint front plate. For control and comparison, the front plate and the circuit board
The supply voltage is 24 V =. The voltage of the valve to be comprise test points for the most important characteristics.
regulated is not supplied via this card. The circuit of the "2-channel card" is designed so that the
Input variables for the cards are the valve position command controllers on basic and daughter card work in a completely
value, the pressure command value, the actual pressure val- independent manner. In this mode, the card is suitable for
ue and possible control mode signals. The pressure sensors controlling 2 valves with integrated electronics (see exam-
with voltage interface receive their voltage supply from the ple 2, page 6).
card (z6/z8). At the card, pressure sensors with voltage and An additional channel mode circuit allows for the consider-
current signal can be connected. able extension of the possible applications of the described
card (see example 1, page 6).
Examples
Example 1
Channel mode "joint output"
Pist
Psoll
Daughter card
Qsoll
p p Pist DIL5
I I
Psoll DIL0
A B Basic card
Channel
Qsoll mode z30
G
P T DIL5
Example 2
Channel mode "separate outputs"
G Directional valve G Directional valve
P P
U U
Actual value p Actual value p

A B A B
G G
P T P T

Pressure Pressure
compensator compensator
Qsoll Qsoll
DIL0 Psoll Psoll

+
Functional presentation
Function and structure of the p/Q controller card are shown If the pressure command value is reached, the limiter takes
as block diagram (see page 3). effect according to the actual pressure value so that the in-
Pressure command value: It is specified by the user in the put signal for the valve position control is changed so that
form of voltage (0...10 V; b12/b14 and/or z10/z12). You can pcommand – pactual = 0 is maintained.
do so by means of a potentiometer which can be supplied Controller characteristic: The PID controller and the
by the card (z32/b8). derivative element can be roughly set by means of DIL
Actual pressure value: It is optionally recorded by pressure switches (printed circuit board) and finely by means of front
sensors with voltage interface (1...6 V, 0...10 V) or current plate switches.
interface (4...20 mA) (which can be switched). Controller display: The controller function is displayed by
The actual pressure value can be tapped as monitor signal means of LED and can be used for switching purposes via
at z16 and/or z18. The command value is compared to the an acknowledgement output.
actual value. The variation and the differentiated actual val- Line break: Simultaneous flashing of the two yellow LEDs
ue act on a PID controller. The controller output signal acts and the switching of output b30 and/or b32 signalizes
on the limiter circuit which influences the position command a pressure sensor line break.
value. If the actual pressure value is smaller than the pres- Controller shut-off: The controller can be shut off by
sure command value, the controller signal is larger than the means of an external signal (6...40 V =).
specified position command value. It is thus not influenced Channel selection: Is only possible for the 2-channel card.
by the limiter; there is simple flow control of the valve. 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 p/Q control signal on the control distance. The DIL switch 0
actual pressure values have to act on one control distance must be ON; otherwise, this special function is blocked. The
via their two independent controllers. An external mode control signal of one channel must be inverted (DIL 5).
signal (z30/6...40 V =) is used to select basic or daughter
DIL 0 Mode signal z30 Basic card I Daughter card II DIL 5 I DIL 5 II
ON H OFF ON – out I (b4/b2) ON OFF
ON L ON – out I (b4/b2) OFF ON OFF
OFF X ON – out I (b4/b2) ON – out II(b6/b8) X X
X– without influence
Principle of the channel selection
p/Q output daughter card
Mode signal
No
DIL0
z30
p/Q output basic card p/Q output

Nc
Setting instructions
A: General instructions E: Comparison of the position signal

– The measured values generally refer to the ground at the – Shut off the p controller (DIL 4)
test point "0 V" – Set the command value amplification using the potenti-
– Indication of the direction of rotation for potentiometers: ometer Qmax..
cw – clockwise ccw – counterclockwise
– Before the commissioning, the position of the setting ele- F: Optimization of the control characteristic
ments is to be checked according to the transfer condition
(see adjustment table page 11) DIL no. Status Function
– Proceed in the order b) to f) (page 10). 6 ON D Pressure normal
OFF build-up reduced 1)
7 ON Pressure normal
B: Mode settings reduction
OFF reduced 1)
DIL no. Status Function 8 ON Share high (9, 10 = OFF)
0 ON Both controllers act on output 1 9 ON Share medium (8, 10 = OFF)
OFF Controller 1 and 2 act on output 1 10 ON Share low (8, 9 = OFF)
and/or 2, irrespective of each other 11 ON I Share = 0 (12 = OFF)
1 ON Pressure sensor 1...6 V/0...10 V 12 ON Share available (11 = OFF)
OFF Pressure sensor 4...20 mA 13 ON P Reduced pres- Valve opening in
2 ON Actual p value amplification sure reduction case of pressure
psys1) ≙ ~ pnom2) reduction
OFF Actual p value amplification < approx.15 %
psys ≙ ~ 0.5 • pnom OFF ineffective
3 ON Cable break detection active 14 ON Share low (16 = ON/15 = OFF)
OFF Cable break detection inactive 15 ON Share medium (14, 16 = OFF)
4 ON p controller active 16 ON Share high (14, 15 = OFF)
1) With DIL 6 and 7 = OFF, DIL 8 is ineffective
OFF p controller shut off,
only the Q signal is analyzed
5 ON p/Q output signal not inverted G: Test points
OFF p/Q output signal inverted The test points of the card may only be loaded with
1) p
sys = System pressure a RL > 10 kΩ. in case of overload, the function of the con-
2) p
nom = Nominal sensor pressure trol is impaired and/or the card is destroyed. The test points
are located on the front plate and laterally on the printed cir-
C: Pressure sensor comparison cuit board.
– Set the sensor type (DIL 1) and the gain factor (DIL 2) Basic card and daughter card have separate test points
each, however the identical reference ground.
– The zero point comparison is effected using the potenti-
ometer pzero in order to achieve 0 V (±10 mV) at the sig-
nal 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 potentiome-
ter Qzero (±10 %). Due to the valve amplifier integrated in the
valve, direct adjustment at the amplifier is not intended.
Controller adjustment
The P, I and D shares of the closed-loop control amplifier Procedure (see table, page 11):
are to be optimized according to the properties of the control An increase in the P share of the controller increases the
distance, the disturbance variables and the static and dy- dynamic of the control behavior (b). In case of excessive
namic requirements on the control result. gain, the tendency to oscillate increases (c).
1) Pressure controller ON – DIL 4 ON Limitation of the I share reduces the static gain. With in-
creasing static gain, the control deviation is reduced (d). The
2) Connection of an oscilloscope at the test point "pactual"
D share can be used to influence the transition behavior
3) Usefully connection of a 2nd oscilloscope channel at the (minimization of the tendency to oscillate); thus, the com-
terminals "pcommand" mand value is only reached after a longer transition time (f).
4) DIL 6 and DIL 7 serve to compensate dynamic differenc-
es 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 (overshoot-
ing tendency with excessive static amplification) and static
accuracy (control error with starting pressure cut off) is to be
achieved (a).
Ideal development
U
P soll
P ist
t
b Problem:
P share too small
U Solution:
→ Rotate Kp against F (fine adjustment)
P soll
→ P gain >
P ist DIL 14 ON
t DIL 15 OFF
DIL 16 ON
c Problem:
P share too large
U
Solution:
P soll → Rotate Kp against 0 (fine adjustment)
→ use DIL 14–16 to reduce the P gain according to the table
P ist
t
d Problem:
P share correct
U Control deviation too large
P ist
Solution:
P soll
→ Increase the I gain share
DIL 11 ON = I share = 0
DIL 12 ON = I share connected
t → Rotate Ki against F
e Problem:
U
Solution:
→ Rotate Ki against F until control deviation and vibration are perfect
P soll
→ If Ki = F is not sufficient, the P share must also be reduced
P ist
t
f Problem:
D share too low
U Solution:
P soll → Rotate KD against F
→ D share >
DIL 8 ON
P ist
DIL 9 OFF
t
DIL 10 OFF
Adjustment table
DIL 16...0 TP 4 TP 5
TP 4: UA
TP 5: 0 V
Basic card * Daughter card

Set by Rexroth 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
DIL switch
DIL switch
DIL 7 OFF DIL 7 ON

DIL 8 OFF DIL 8 OFF
DIL 9 OFF DIL 9 OFF
DIL 10 OFF DIL 10 OFF
DIL 15 ON DIL 15 ON
HEX KP B HEX KP 3
HEX code
HEX code
HEX KI 1 HEX KI 9
HEX KD D HEX KD 5
* Only with 2-channel variant
DIL switch HEXCODE switch

1
ON ON
ON
OFF D 5
5 4 3 2 1
9
Unit dimensions (dimensions in mm)
35
Plug-in connector
DIN 41612 - F 32
100
24 V= Mains
160

– 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.
of wear and aging.
Δp/Q controller RE 30136/07.12
Replaces: 05.04
1/16
Type VT-VACAF
Component series 1X

Contents 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
Front plate 2 in 19 " racks
Block diagram with pin assignment 3 – Pressure differential controller (force controller) with
PID behavior
Wiring diagram with valve amplifier card 4
– Short-circuit-proof outputs
Wiring diagram – Valve with installed electronics 5
– External shut-off for pressure controller
Technical data 6
– Monitor signal for controller
Functional principle 7
– Separate acceleration and braking ramp
Additional information 7
– Ramps can be separately adjusted and switched off
Examples 8
– Adjustable area adjustment for cylinder
Function 9
– Suitable for pressure sensors (0...10 V, 4...20 mA),
Settings DIL switch 10
Commissioning and adjustment 12
– Supply for pressure sensors
Adjustment protocol 15
– Cable break detection for pressure sensor
Device dimensions 16
Notice:
2/16 Bosch Rexroth AG Hydraulics VT-VACAF RE 30136/07.12
VT V A C A F 500 10 V0
Hydraulic component
(control) Customer version
Axis control =A V0 = Catalog version
Valve type 1X = Component series 10 to 19
High-response valve =C (10 to 19: Unchanged technical data
Control and pin assignment)
Analog =A Serial number for types
Function 500 = Standard variant without valve amplifier function
Δp/Q control =F
Preferred types
Amplifier type Material number
VT-VACAF-500-10/V0 0811405147

Only for control cabinet installation.
Front plate
green Controller is working

green UB ON yellow Controller not active
off Δp controller OFF
UB
QCommand gain Q max KP Hex KP

Ramp A OFF A Ramp B Ramp B OFF
off
TP QCommand Q soll KI Hex KI
– zero
Zero point Np Psoll TP pcommand
+ valve
TP Valve KD Hex KD
Pist
TP pactual B A TP pactual
Pressure – Pnull –
Zero point Np Zero point Np Pressure sensor A
sensor B + +
Gain Gain
B
Area adjustment fine
Area adjustment 0V
Pdiff
coarse
TP 0V
TP pdiff
24 V <21 V Outputs
Inputs 1
< 21 V
z4 UB ON/UB
+UB
z2 +10 V z32 +10 V/10 mA
UB +24V DC –10 V b32 10 V/10 mA
b2 +15 V z6 +15 V/100 mA
0V
Power zero DC –15 V z8
b4 15 V/100 mA
0V b12
+24 V 0 V Control zero
z28 b14
Control zero 0 V
b12 24 V=
b14 DIL3 DIL6-10 KD DIL11-13 KP KI DIL15,16
RE 30136/07.12 VT-VACAF
b8 1:1-1:4 b22 Pressure sensor

Gain DG B
1 50...100% 24 V
Tp"pB"
0...0,25% TV 0V
Pressure sensor B z30
4…20 mA 200 Ω – –
z14 Σ
Area ad- KP
justment
+ 24 V=
Pressure sensor B
b16 +5 %
0…10 V External
+ Np DG B TI
b18 – +10 V Tp"pAB"
z24 controller enquiry
0V Gain DG A 24 V
Pressure sensor A b30 50...100% ON 0V
4…20 mA 200 Ω z16 Monitor signal
b24 p controller
DIL1 Pressure controller
Pressure sensor A Tp"pA" + 10 V
b26 +5 % ON/OFF
0…10 V + Np DG A
+10 V +10 V
b28 – α β γ δ
0V
Tp"psoll diff" OFF

z10
Command + 10 V
+
value pDiff z12
0V – b8
0 V (E)
DIL0 Tα,β =0 Tα,δ =0
Ramp A z22 Q+ Np
8…40 V= +5 %
OFF DIL2 Q– Valve output
z26 Valve
Ramp B 8…40 V=
OFF b20 b6
+ 10 V + + 10 V (Q)
Command z20 – Ramp A DIL5
0V Ramp B Gain Qsoll Δ P/Q
value Q Tp"Qsoll" 50...100%
b10 OFF OFF 1
p controller 6…40 V=
OFF DIL4
3/16
Neutral point 0 V
4/16
+24V
St –0 V L –0 V St –0 V
b14
b12
z28
b4
z4
b2
z2
z2
b2
b4
z4
z28
Monitor signal + 10 V z16
p controller
SPS External 24 V z24
controller enquiry 0V
24 V b22
Bosch Rexroth AG Hydraulics
Pressure sensor 0V
b26
b6 b20
z30
p controller OFF 6…40 V= b10 Δ p/Q
b8 z20 b28
b30
Ramp OFF 6…40 V= z22
A
Wiring diagram with valve amplifier card
b22
SPS z32 10 mA
Ramp OFF z26 +10 V z30
B 6…40 V=
b32 10 mA b24
b20 10 V
10...+10 V b30
Command z6 100 mA
+15 V
value Qcommand Ref–0 V z20
z8 100 mA
15 V
10...+10 V z10 b6
Command value pDiff
Ref–0 V z12 z22 b8
1 2 1 2 3 4 1 2 3 4
b16
b18
z14
z30
b26
b28
b24
b30
z16
24 V
0V
B A
U I U I Valve U
p p p p s
8,5…40 V=
Enable
or or
U
s
VT-VACAF RE 30136/07.12
Neutral point 0 V
+24V
2.5 AF
b14
b12
z28
b4
z4
b2
z2
+ 10 V z16
Monitor signal p controller
RE 30136/07.12 VT-VACAF
SPS External 24 V z24

controller enquiry 0V
24 V b22
Pressure sensor 0V A
B
p controller OFF 6…40 V= b10 b6 C
Δ p/Q
D
E
Ramp OFF 6…40 V= z22 b8 F U s
A
SPS
Ramp OFF B 6…40 V= z26
U s
10...+10 V b20 z32 10 mA

Wiring diagram – Valve with installed electronics
Command +10 V
value Qcommand z20 b32 10 mA
Ref–0 V 10 V
10...+10 V z10 z6 100 mA
Command value pDiff
+15 V
Ref–0 V z12 z8 100 mA
15 V
b16
b18
z14
z30
b26
b28
b24
b30
B A
U I U I Ref–0 V + 10 V
p p p p
Actual value valves
or or
5/16

Current consumption, max. mA 250
Command value Q b20: 0...±10 V
z20: 0...±10 V ｝
Differential amplifier
(Ri = 100 kΩ )
Command value pdiff z10: 0...±10 V
z12: 0 V ｝
Actual value from the pressure sensor A b26: 0...+10 V
b28: 0 V ｝
b24:
b30: 4...20 mA
B b16: 0...+10 V
b18: 0 V ｝
b14:
b30: 4...20 mA
Pressure sensor supply z6: +15 V, max. 100 mA
z8: –15 V, max. 100 mA
Pressure controller OFF b10: 6...40 V =
External controller enquiry z24: 24 V/0.1 A max., if controller is not active
Signal source Supply ±10 V from b32, z32 (10 mA) or external signal source
Monitor signal Factual z16: ±10 V
Error pressure sensor b22: No error: +UB; max. 100 mA
(cable break, signal lines) Error: 0 V
: LED "Ramp A OFF" and
"Ramp B OFF" flash
Ramp times Min. 350 ms (1)
Max. 5.6 s (16) ｝ 16 steps
350 ms/step
Ramp OFF A z22: 8...40 V =
B z26: 8...40 V =
Area adjustment cylinder Min. 1:1 (1)
Max. 1:4 (16) ｝ 16 steps
LED displays red: Error UB

red: Ramp A OFF
red: Ramp B OFF
green/yellow:
green: Controller active
yellow: Controller not active
off: Controller OFF
Format of the printed circuit board mm (100 x 160 x approx. 35) / (W x L x H)
Europe format with front plate 7 TE
Weight m 0.44 kg
Notice:
Power zero b2 and control zero b12 or b14 or z28 must be separately led to the central ground (neutral point).
RE 30136/07.12 VT-VACAF Hydraulics Bosch Rexroth AG 7/16
Functional principle
Force control
p p
U U
B A
Δ p soll
Qsoll
Applications
As opposed to p/Q control, pressure measurement in the A The command value ramps allow for the design of command
and B line of a hydraulic actuator by means of the "Pressure value steps of Δpcommand as ramp function. The error moni-
differential controller" printed circuit board can be used to al- toring logic detects cable break of the signal lines of the sen-
low for Δp/Q control of the actuator. sors and errors in the voltage supply. The pressure control
Consequently, this control structure is used everywhere circuit can also be switched off externally (flow control).
where you don't only have to control the pressure in one di- To control the actuator, this printed circuit board is to be
rection of motion of the actuator against a constant pressure coupled with a valve amplifier card or a valve with in-
but where there is also pressure control against a changing stalled electronics.
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.
Examples
Example 1
Welding machine
Welded seam
p p
U U
Δ p soll
Δ p/Q Qsoll
Example 2
Vehicle twisting test stand
p
U
p
U
Δ p soll
Δ p/Q Qsoll
P
Function
Input variables are the differential pressure Δp and flow Q The command value Q corresponds to the spool path as
command values. As actual values, pressure differential and long as the pressure control does not take effect, yet, i.e.
valve spool path are fed back. Δpcommand > Δpactual or if the pressure controller is switched off.
The Δp/Q controller takes effect: The command value Q may range between UE = 0...±10 V.
a) As long as Δpcommand > Δpactual like a flow control, i.e. the
pressure control does not yet take effect;
b) If Δpcommand = Δpactual, the pressure control takes effect,
i.e. a limiter superimposes the command value Q.
Functional examples
Qcommand Direction pdiff. command Direction Track traveling Force control
+5.0 V +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
↓ 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.
Settings DIL switch
DIL no. Status Function

0 ON External ramp control possible
A
OFF + pdiff. command via ramp
1 ON 4...20 mA pressure sensors
OFF 0...10 V pressure sensors
2 ON External ramp control possible
B
OFF + pdiff. command via ramp
3 ON Cable break detection p sensor ON
OFF Cable break detection OFF
4 ON External controller shut-off possible
OFF External controller shut-off not possible
5 ON/OFF Inversion of the hydraulic direction of action
→ +QCommand must extend the cylinder
6 OFF Switch combinations,
7 OFF see table 1
D share
8 OFF
9 OFF
10 OFF
11 OFF Switch combinations,
12 ON see table 2
P share
13 OFF
14 ON Reduced pressure decrease with pdiff. actual > pdiff. command
Valve opening max. 20 %
OFF No reduced pressure reduction
15 ON Switch combinations, see table 3
I share
16 OFF
Ramps
DIL
α β γ δ 5 ........ 0
6 . . . . . . 10 11 . . . . . . . .16
DIL OFF
ON
Without function OFF

ON
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 DIL 9 DIL 10 Effect
OFF OFF OFF OFF OFF No influence on the
OFF OFF ON OFF OFF hex switch KD
OFF ON OFF OFF OFF
OFF ON ON OFF OFF
ON OFF OFF OFF OFF
ON OFF ON OFF OFF
ON ON OFF OFF OFF
ON ON ON OFF OFF
1 OFF OFF OFF OFF ON Direction 1
OFF OFF OFF ON OFF Direction 2
OFF OFF OFF ON ON Direction 1 + 2
2 ON OFF OFF OFF ON Direction 1
ON OFF OFF ON OFF Direction 2
ON OFF OFF ON ON Direction 1 + 2
3 OFF ON OFF OFF ON Direction 1
OFF ON OFF ON OFF Direction 2
OFF ON OFF ON ON Direction 1 + 2
4 ON ON OFF OFF ON Direction 1
ON ON OFF ON OFF Direction 2
ON ON OFF ON ON Direction 1 + 2
5 OFF OFF ON OFF ON Direction 1
OFF OFF ON ON OFF Direction 2
OFF OFF ON ON ON Direction 1 + 2
6 ON OFF ON OFF ON Direction 1
ON OFF ON ON OFF Direction 2
ON OFF ON ON ON Direction 1 + 2
7 OFF ON ON OFF ON Direction 1
OFF ON ON ON OFF Direction 2
OFF ON ON ON ON Direction 1 + 2
8 ON ON ON OFF ON Direction 1
ON ON ON ON OFF Direction 2
ON ON ON ON ON Direction 1 + 2
Direction 1 ≙ force reduction
Direction 2 ≙ force build-up
Table 2
DIL 11 DIL 12 DIL 13 Effect

OFF OFF OFF No gain reduction to hex
OFF OFF ON switch KP
ON OFF ON Low gain

OFF ON OFF Medium gain
ON ON OFF
ON OFF OFF High gain
ON ON ON Forbidden
OFF OFF OFF
Table 3
DIL 15 DIL 16 Effect

OFF OFF No influence on the hex switch KI
OFF ON I share = 0
ON ON
ON OFF I max. (≙ KI = 16) + KI current
Commissioning and adjustment

General notes:
Setting during the commissioning is effected using potenti- Overload impairs the control function and/or the printed cir-
ometers and HEXCODE switches on the front plate as well cuit board is damaged. Before the commissioning, the basic
as using DIL switches on the printed circuit board. settings of the as-delivered state are to be checked. In the
Test points for voltage measurements as well as LED dis- card adjustment, proceed in the order of the points shown
plays are located on the front plate. The measured values (see page 13).
generally refer to the test point 0 V. The test points may only
be loaded with measuring devices RL ≧ 10 kΩ.
– Electrical
Verification of the According to connection diagram, page 4 and/or 5
connections – Hydraulic
Pressure sensor A for piston chamber
Pressure sensor B for annulus area.
– According to the table, page 15,

Default setting controller column as-delivered state.
parameters
– Carry out the settings according to the table, page 10.

Mode settings
DIL 0...5
– Set an area ratio 1:1.

Pressure sensor – System depressurized: Zero point adjustment
adjustment → Potentiometer pzero → TPP actual = 0 V.
– Max. system pressure: Gain adjustment
→ Potentiometer → TPP actual = 10 V.
– Set the hex switch to the area ratio of

Setting of the cylinder the cylinder; potentiometer to ccw.
area ratio 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
Adjustment Qmax. 10 V at TP-QCommand.
– Specification QCommand = 0 V → The forces at

the cylinder must be balanced (i.e. pressure
Valve zero point adjustment ratio pK:pR must correspond to the ratio AK:AR).
– Working in the control loop

→ Specification of command value steps pdiff.
Controller adjustment (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.
a Ideal development
(only a square is shown)
U
P soll
P ist
t
b Problem:
P share too low
U Solution:
→ Rotate Kp against 16
P soll (fine adjustment)
→ P gain >
see table 2, DIL 11–13
P ist
t
c Problem:
P share too large
U Solution:
→ Rotate Kp against 1
P soll (fine adjustment)
→ Use DIL 11–13
to reduce the P gain
P ist
according to table 2
t
d Problem:
P share correct,
control deviation too large
U
P ist Solution:
→ Increase the I gain share
P soll according to table 3
→ Rotate KI against 16
e Problem:
U Solution:
→ Rotate KI against 16 until control
P soll deviation and vibration are perfect
→ if KI = 16 is not sufficient,
the P share must also be
P ist
reduced, see table 2
t
f Problem:
D share too low
U Solution:
P soll → Rotate KD against 16
→ D share >, see table 1
(DIL 6–10)
P ist
t
Adjustment protocol
Created by Switches As-delivered state
↓
DIL 0 ON
DIL 1 ON
Date 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
Device dimensions (dimensions in mm)
35
Connector
DIN 41612 - F 32
100
24 V= Mains
160

– The valve solenoid must not be connected to free-wheeling diodes or other protection circuits.
of wear and aging.
Digital axis control RE 30139-B/10.11
Replaces: 04.10
Type VT-HNC100...3X English
Operating Instructions
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
6 Assembly........................................................................................................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
7 Commissioning..............................................................................................37
7.1 First commissioning.................................................................................37
7.2 Commissioning software WIN-PED® 6 and
WIN-PED® 7............................................................................................37
7.3 Installation requirements..........................................................................38
8 Operation........................................................................................................41
8.1 Software description................................................................................41
9 Maintenance and repair.................................................................................42
9.1 Cleaning and care....................................................................................42
9.2 Maintenance............................................................................................42
9.3 Repair......................................................................................................42
10 Disassembly and replacement.....................................................................43
10.1 Preparing for disassembly.......................................................................43
10.2 Disassembling the digital axis control......................................................43
10.3 Preparing the components for storage/further use.................................. 43
11 Disposal..........................................................................................................44
11.1 Environmental protection.........................................................................44
11.2 Return to Bosch Rexroth.........................................................................44
11.3 Packagings..............................................................................................44
11.4 Materials used.........................................................................................44
11.5 Recycling.................................................................................................44
12 Extension and conversion............................................................................45
13 Troubleshooting............................................................................................45
13.1 How to proceed with troubleshooting.......................................................45
14 Technical data................................................................................................46
15 Appendix........................................................................................................ 47
15.1 Address 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 RE 30139 Technical data sheet
VT-HNC100...3X Available on the
Internet under www.
boschrexroth.
com
Declaration on the environmental RE 30139-U Environmental
compatibility for EMC, climate and statement
mechanical load Available on the
Internet under www.
boschrexroth.
com
Online help in the commissioning Available on the
software Internet under www.
WIN-PED® 6 and/or WIN-PED® 7 boschrexroth.
com/hnc100
“First steps” towards WIN-PED Available on the
Internet under www.
boschrexroth.
com/hnc100
General product information on RE 07008 Available on the
hydraulic products Internet under www.
boschrexroth.
com
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
Indicates a dangerous situation which may cause death
WARNING or severe personal injuries if not avoided
Indicates a dangerous situation which may cause minor
CAUTION 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

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
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.
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 support.nc-system@boschrexroth.de.
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.
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 extra-
low 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.
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 15-
pole)
•• Mating connector X8M (Type Phoenix Micro Combicon 8-pole or HD-SUB 15-
pole)
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.
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.
Setup example
1$ 1-$ ).*
)JHIFSMFWFMDPOUSPM 1-$PS1$
BOEWJTVBMJ[BUJPO ).*
%JHJUBMJOQVUTPVUQVUTPSCVTTZTUFN
(MPCBMCVT 130'*#64%1 $"/PQFO 130'*/&535 &UIFS/FU*1
$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
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 3X
VT-HNC100 = Serial unit Option

Version Compact for 1 axis =C 000 = without synchronization
Version for 1 hydraulic axis =1 G02 = Synchronization 2-axis version
G03 = Synchronization 3-axis version
Version for 2 hydraulic axes =2
G04 = Synchronization 4-axis version
Version for 3 hydraulic axes =3
Version for 4 hydraulic axes =4 00 = No fitting
E0 =TCP/IP 1)
Component series 30 to 39 = 3X
(30 to 39: unchanged technical data and pinout) Position transducer
I = Incremental/SSI
(not in connection with Compact version)
S = SSI
(only in connection with Compact version)
Bus connection 2)
P = 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 without bus connection are not available.
Fig. 2: Order code

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!
X8M Encoder X3C RS232

Pin Pin
8 Shield 1
7 24 Venc 2 TxD
6 +5 V 3 RxD
5 – Clk 4 reserved
4 + Clk 5 GND
3 – Data 6 reserved
2 + Data 7 reserved
1 EGND 8 reserved
9

X2D DIO (digital) X1S Power
Pin Pin
8 Shield 1 GND

7 OUT2 2 GND

6 OUT1 3 18 – 30 V

5 IN4

4 IN3
3 IN2
X7P PROFIBUS DP

2 IN1
Pin
1 DGND 1 reserved

2 reserved

3 RxD/TxD-P
4 CNTR-P
5 DGND
X2A AIO (analog)
6 VP
Pin
7 reserved
8 Shield
8 RxD/TxD-N

7 24 Vsens
9 reserved
6 Vout1 +
5 Vout2 +

4 Vin1
3 Cin2 +
X7C CANopen

2 Cin1 + Pin
1 AGND 1 reserved
2 CAN_L
3 CAN_GND
4 reserved
5 reserved
6 reserved
7 CAN_H
8 reserved
9 reserved
4.4.2 Pin assignment VT-HNC100-1-3X/...

(1-axis version)
X3C RS232 Slot 1 X8M1 Encoder

Pin
Incremental SSI
1
Pin 1 – B (Inc)
2 TxD
2 + CLK (SSI)
3 RxD
3 + R (Inc)
4 reserved
4 – R (Inc)
5 GND
5 + A (Inc)
6 reserved
6 – A (Inc)
7 reserved
7 – CLK (SSI)
8 reserved
8 + B (Inc)
9
9 – Data (SSI)
10 EGND
11 + Data (SSI)
X1S Power 12 +5 Venc Slot 1 X2D1 DIO
Pin 13 +10 Vref (Digital)
1 GND 14 +24 Venc Pin 1 I/O 1
2 GND 15 reserved 2 I/O 2
3 18 – 30 V 3 I/O 3
4 I/O 4
5 I/O 5
6 I/O 6
X7E1, X7E2 7 I/O 7
Ethernet 8 I/O 8
connection
9 I/O 9
10 I/O 10

11 I/O 11
12 DGND
X7P PROFIBUS DP
Pin

1 reserved

2 reserved

3 RxD/TxD-P

4 CNTR-P
5 DGND Slot 1 X2A1 AIO

(Analog)
6 VP

Pin 1 Vin1 +
7 reserved

8 RxD/TxD-N 2 Vin1 –

9 reserved 3 Vin2 +

4 Vin2 –

5 Cin1 +

X7C CANopen 6 Cin1 –

7 Cin2 +
Pin

8 Cin2 –
1 reserved
9 reserved
2 CAN_L

10 AGND
3 CAN_GND

11 Vout1 +
4 reserved
12 Vout2 +
5 reserved
13 Cout1
6 reserved
14 +24 Vsens
7 CAN_H
15 reserved
8 reserved

9 reserved

(2-axis version)

Pin Slot 2 X8M2
1 Incremental SSI
2 TxD
Pin 1 – B (Inc)
3 RxD
2 + CLK (SSI)
4 reserved
3 + R (Inc)
5 GND
4 – R (Inc)
6 reserved
5 + A (Inc)
7 reserved
6 – A (Inc)
8 reserved
7 – CLK (SSI)
9
8 + B (Inc)
9 – Data (SSI)
10 EGND
X1S Power 11 + Data (SSI) Slot 1 X2D1 DIO 1)
Pin Slot 2 X2D2 (Digital)
12 +5 Venc
1 GND Pin 1 I/O 1
13 +10 Vref
2 GND 2 I/O 2
14 +24 Venc
3 18 – 30 V 3 I/O 3
15 reserved
4 I/O 4
5 I/O 5
6 I/O 6
X7E1, X7E2
7 I/O 7
Ethernet
8 I/O 8
connection
9 I/O 9
10 I/O 10

X7P PPROFIBUS DP 11 I/O 11

12 DGND
Pin
1 reserved

2 reserved

3 RxD/TxD-P

4 CNTR-P
5 DGND

Slot 1 X2A1 AIO
6 VP Slot 2 X2A2 (Analog)

7 reserved
Pin 1 Vin1 +

2 Vin1 –
8 RxD/TxD-N

3 Vin2 +
9 reserved

4 Vin2 –

5 Cin1 +

X7C CANopen 6 Cin1 –

Pin 7 Cin2 +

1 reserved 8 Cin2 –
2 CAN_L 9 reserved

3 CAN_GND 10 AGND

4 reserved 11 Vout1 +
5 reserved 12 Vout2 +
6 reserved 13 Cout1
7 CAN_H 14 +24 Vsens
8 reserved 15 reserved
9 reserved
1) A maximum of 20 digital outputs can be connected.


(3-axis version)

Pin Slot 2 X8M2
1 Slot 3 X8M3
Incremental SSI
2 TxD
Pin 1 – B (Inc)
3 RxD
2 + CLK (SSI)
4 reserved
3 + R (Inc)
5 GND
4 – R (Inc)
6 reserved
5 + A (Inc)
7 reserved
6 – A (Inc)
8 reserved
7 – CLK (SSI)
9
8 + B (Inc)
9 – Data (SSI)
10 EGND Slot 1 X2D1 DIO 1)
X1S Power
11 + Data (SSI) Slot 2 X2D2 (Digital)
Pin 12 +5 Venc Slot 3 X2D3
1 GND 13 +10 Vref Pin 1 I/O 1
2 GND 14 +24 Venc 2 I/O 2
3 18 – 30 V 15 reserved 3 I/O 3
4 I/O 4
5 I/O 5
X7E1, X7E2
6 I/O 6
Ethernet
7 I/O 7
connection
8 I/O 8
9 I/O 9
10 I/O 10

11 I/O 11
12 DGND
X7P PROFIBUS DP
Pin

1 reserved

2 reserved
3 RxD/TxD-P

4 CNTR-P
Slot 1 X2A1 AIO
5 DGND
Slot 2 X2A2 (Analog)
6 VP
Slot 3 X2A3

7 reserved
Pin 1 Vin1 +
8 RxD/TxD-N

9 reserved

2 Vin1 –

3 Vin2 +

4 Vin2 –

5 Cin1 +
X7C CANopen
6 Cin1 –
Pin
7 Cin2 +
1 reserved
8 Cin2 –
2 CAN_L

9 reserved
3 CAN_GND
10 AGND

4 reserved
11 Vout1 +
5 reserved
12 Vout2 + 2)
6 reserved
13 Cout1
7 CAN_H
14 +24 Vsens
8 reserved
15 reserved
9 reserved
2) Not available at slot 3 (reserved).

(4-axis version)
X3C RS232 Slot 1 X8M1 Encoder Slot 1 X2D1 DIO 1) Slot 1 X2A1 AIO
Pin Slot 2 X8M2 Slot 2 X2D2 (Digital) Slot 2 X2A2 (Analog)
Slot 3 X8M3 Slot 3 X2D3 Slot 3 X2A3
1
Slot 4 X8M4 Slot 4 X2D4 Slot 4 X2A4
2 TxD
Incremental SSI Pin 1 I/O 1 Pin 1 Vin1 +
3 RxD
Pin 1 – B (Inc) 2 I/O 2 2 Vin1 –
4 reserved
2 + CLK (SSI) 3 I/O 3 3 Vin2 +
5 GND
3 + R (Inc) 4 I/O 4 4 Vin2 –
6 reserved
4 – R (Inc) 5 I/O 5 5 Cin1 +
7 reserved
5 + A (Inc) 6 I/O 6 6 Cin1 –
8 reserved
6 – A (Inc) 7 I/O 7 7 Cin2 +
9
7 – CLK (SSI) 8 I/O 8 8 Cin2 –
8 + B (Inc) 9 I/O 9 9 reserved
9 – Data (SSI) 10 I/O 10 10 AGND
10 EGND 11 I/O 11 11 Vout1 +
X1S Power 12 DGND 12 Vout2 + 2)
11 + Data (SSI)
Pin 12 +5 Venc 13 Cout1
1 GND 13 +10 Vref 14 +24 Vsens
2 GND 14 +24 Venc 15 reserved
3 18 – 30 V 15 reserved
X7E1, X7E2

Ethernet
connection

X7P PROFIBUS DP
Pin
1 reserved

2 reserved

3 RxD/TxD-P

4 CNTR-P

5 DGND
6 VP

7 reserved

8 RxD/TxD-N
9 reserved

X7C CANopen

Pin

1 reserved

2 CAN_L

3 CAN_GND

4 reserved
5 reserved
6 reserved
7 CAN_H
8 reserved
9 reserved

2) Not available at slot 3 and slot 4 (reserved).
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.
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.
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 R901189300
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
Cable set VT17220-1X/HNC100...3X, length 2 m,for analog R901189302
signals (connection X2A) and digital position measurement
systems (connection X8M) with FK MC connector and open
breakout cable for: VT-HNC100-C-3X
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.
Assembly
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
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
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.
Assembly
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
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 5 6
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 Shield put over outer

using a shrinkable tubing 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
6 Wire end ferrules
NOTE: Type and manufacturer of item 2 are binding (housing dimensions)!

Assembly
Table 7: Pin assignment
Slot X2A1 AIO (analog) Slot 1 X8M1 Encoder

Incremental SSI
1 Black
Pin 1 Vin 1 + Pin 1 –B
2 Pink Pin 2 Vin 1 – Pin 2 + CLK
3 Grey/Pink
Pin 3 Vin 2 – Pin 3 +R
4 Red/Blue
Pin 4 Vin 2 – Pin 4 –R
5 White/Green
Pin 5 Cin 1 + Pin 5 +A
6 Brown/Green
Pin 6 Cin 1 – Pin 6 –A
7 Grey Pin 7 Cin 2 + Pin 7 – CLK
8 Violet Pin 8 Cin 2 – Pin 8 +B
9 Yellow Pin 9 reserved Pin 9 – Data
10 White + Blue
Pin 10 AGND Pin 10 EGND
11 Green
Pin 11 Vout 1 Pin 11 + Data
12 Brown
Pin 12 Vout 2 Pin 12 +5 Venc
13 White/Yellow
Pin 13 Cout 1 Pin 13 +10 Vref
14 Red
Pin 14 24 Vsens Pin 14 +24 Venc
15 Yellow/Brown
Pin 15 reserved Pin 15 reserved
VT-HNC100 Compact
HNC100...3X shield system:
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
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
Printed on the cable on both ends (smear-resistant, text height 3 mm)
Shrink shield onto cable sheath
Shrink black litz wire using a shrinkable tubing
after soldering
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

3 Unitronic LiYCY cable 4 x 2 x 0.25 mm2, approx. 2.2 m long
5 Wire end ferrules
Assembly
Table 8: Pin assignment
8
Black
Slot X8M Encoder Slot X2A AIO
7 Red (Analog)
Pin 8 Shield Pin 8 Shield
6 Brown
Pin 7 24 Venc Pin 7 24 Vsens
5 Grey
Pin 6 +5 V Pin 6 Vout 1
4 Pink Pin 5 – Clk Pin 5 Vout 2
3 Yellow Pin 4 + Clk Pin 4 Vin 1
2 Green Pin 3 – Data Pin 3 CIN2 +
1 Blue + White Pin 2 + Data Pin 2 CIN1 +

Pin 1 EGND Pin 1 AGND
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

Assembly
Fig. 12: Wiring for pressure transducers

Assembly
Fig. 13: Forwarding a pressure transducer signal (not for Compact version)
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

Assembly
Fig. 15: VT-HNC100 address with CANopen
Fig. 16: Baud rate for CANopen

Assembly
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

Assembly
Fig. 18: Address setting for PROFIBUS DP

Assembly
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.
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.
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.
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.
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
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 VT-
HNC100...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”.
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.
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.
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
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.
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 PROFINET RT EtherNet/IP

Functionality PROFINET IO RT Device EtherNet/IP adapter
Conformance Class A Remote Reset: 0/1
Protocols (CM, RTC, RTA, ARP, ICMP, Connection Classes 1/3(Exclusive Owner,
LLDP) Listen Only)
Alarm support Unconnected Explixit Messaging
Max. 1 API supported DHCP support
Minimum cycle time 2 ms
Max. size of the cyclic I/O data 992 byte (max. 496 496 byte per direction)
Transmission rate 100 Mbit/s, full-duplex
Interface 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 Conformity with the relevant IE standard
Diagnosis LED 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
Appendix
15 Appendix
15.1 Address directory
15.1.1 Contact 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: service@boschrexroth.de
15.1.2 Contact 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: support.nc-system@boschrexroth.de
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 9352 18-0
Fax +49 9352 18-23 58
info@boschrexroth.de
www.boschrexroth.com
Subject to change without notice

Printed in Germany
RE 30139-B/10.11
VT-HACD-1 – Digital controller RE 30143-B/08.07
Replaces: 04.07
for electromechanical
and electrohydraulic drives
Installation and Operation

2/48 Bosch Rexroth AG | Hydraulics Installation and Operation | RE 30143-B/08.07
RE 30143-B/08.07 | Installation and Operation Hydraulics | Bosch Rexroth AG 3/48
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

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
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. Infor-
mation 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 Electrome-
chanical 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)
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 cur-
rent which, if not avoided, could result in death or serious injury.
Equipment damage
This symbol pertains to actions which could result in damage to e-
quipment.
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
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 op-
tion:
VT-NE30
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 in-
structions in the included documentation.
When faults occur, which compromise safety and result in changes in operating condi-
tions, shut down the controller card immediately and notify responsible personnel.
Fault free and safe running of the controller card assumes appropriate transport, stor-
age 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 Manufac-
turers Association (NEMA), as well as local standards should be observed. The op-
erator is required to adhere to the above named standards at all times.
Proper Use
The HACD controller card is designed for controlling electromechanical and electro-
hydraulic drives.
Applications include:
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. There-
fore 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 regu-
lations contained in the accompanying documentation.
Work on the electrical equipment must be performed only by qualified special-

ists 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 train-
ing, as well as knowledge of the relevant standards, is able to evaluate the tasks as-
signed 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 con-

nections 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 con-
tacts (low voltages, low currents)
Always shield all analog signal lines. Connect shields at the card end only, con-
necting 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 con-
troller 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 Com-
ponents" EN982:1996).
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 neces-
sary. Use insulated tools only
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
ATTENTION ATTENTION ACHTUNG
Static Sensitive Circuits sensibles à Elektrostatisch gefährdete
Devices l' électricité statique. Bauelemente.
Handle only at Manipulation uniquement Handhabung daher nur an

Static Safe Work autorisée sur un poste de geschützten Arbeitsplätzen
Stations travail protégé. erlaubt.
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 work-
ing 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.
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.
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 pre-
vented 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

log 1 = 16..Ub

log 1 = 16..Ub

log 1 = 16..Ub

log 1 = 16..Ub

log 1 = 16..Ub

log 1 = 16..Ub

log 1 = 16..Ub

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 CAN Specification

Input/Output

protected
28 Data – Local CAN Bus CAN Specification

Input/Output
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
Row b:
2 AI3+ Differential input Differential input:

± 10V (Rin>100kΩ),
4 AI3- Differential input 0...20mA with Rin = 100Ω

± 10V (Rin>100kΩ),

± 10V (Rin = >10MΩ),

± 10V (Rin>100kΩ),

± 10V (Rin>100kΩ),

± 10V (Rin>100kΩ),
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
Row z
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

protected

protected

protected

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
Row f

protected
4 SSI Clk + Clock output 5V Signal RS-485 compatible

SSI encoder
6 SSI Clk - Clock output 5V Signal RS-485 compatible

SSI encoder
8 SSI Data+ / Data input 5-24V Signal

INC Ua1 SSI encoder
10 SSI Data - / Data input 5-24V Signal

INC /Ua1 SSI encoder
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
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 com-
municate 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 ad-
dress.
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.
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)
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 monitor-
ing 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 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
Software 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.
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 require-
ments 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.
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.
4 HACD Operation
Serial Port The serial port on the front panel is configured as a standard RS-232 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.
Profibus Port The Profibus DP V0 interface on the faceplate is a 9-pin D-Sub connector as descibed
(optional) 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 MSB
1 2 4 8 16 32 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”.
HACD Operation 4
4.2 Diagnostics Test Jacks
The diagnostic test jacks on the front panel of the card can be used to connect exter-
nal test instruments. Two analog voltage signals are available to perform measure-
ments.
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 but-
tons 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 "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”.
HACD Operation 4
Level 1 Level 2 Level 3 Level 4 Level 5 Level 6

Parameter
Use "ENTER" Block 1~32
to go to menu
Loop 1
Command parameter
Command Unit
[-50000.00~+50000.00] Units
Velocity+ Unit/s
[0~5000.0] Units/sec
Velocity- Unit/s
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
[0~640] Hz
T1 Lag Hz
[0~640] Hz
Feed Fwd %
[0.00~1.00]
Loop 2
Commad Parameter
Command Unit
[-50000.00~+50000.00] Units
Velocity+ Unit/s
Velocity- Unit/s
S-Ramp Start s
[0.00~60.00] Sec
S-Ramp end s
[0.00~60.00] Sec
Fig. 6 Menu tree "Parameter Part 1"

4 HACD Operation
Control parameter
P
[-50000.00~+50000.00] Units
I ms
I on |CMD-LFB|< Unit
I on |CMD-LFB| > Unit
[0.00~60.00] Sec
DT1 Hz
[0~640] Hz
DT1(LFB2) Hz
[0~640] Hz
T1 Lag Hz
[0~640] Hz
Feed Fwd %
[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]

HACD Operation 4
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+ %
[0.0~+100.0]
Residual- %
[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]

4 HACD Operation
Setup
Press “ENTER + ESC“ Language
to go to the configura- German
tion menu
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 suc-
cessfully to the memory.
HACD Operation 4
Valve Menu *
Press “ENTER + ESC“ Off
to go to the configura- Direct
tion menu
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

4 HACD Operation

Analog I/O
Press “ENTER + ESC“ Inputs
to go to the configura- AI1
tion menu
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"

HACD Operation 4
AO2
Range
+/-100 %
[0~+100] %
Offset
[-100.0~+100.0]
Fig. 12 Menu tree "Analog I/O Part 2"
Digitale I/O
Press “ENTER + ESC“ Inputs
to go to the configura- Binary Mode
tion menu
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“

4 HACD Operation
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“

Test Jacks
Press “ENTER + ESC“ X1
to go to the configur- Signal
ation menu 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“

HACD Operation 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“

4 HACD Operation
Faults
Press “ENTER + ESC“ Analog Inputs
to go to the configura- AI1
tion menu
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"

HACD Operation 4
4.4 Display/Input Key Operations
All operations can be performed directly on the card using the "UP", "DOWN", "EN-
TER" 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 Pressing the "UP" key moves in the upward direction, within the selected level, to
UP available menu items. (for an overview, see section 4.3: "Menu tree for settings and
parameters")
z Pressing the "DOWN" key moves in the downward direction, within the selected level,
DOWN to available menu items (for an overview, see section 4.3: "Menu tree for settings
and parameters").
Change menu mode:
z Press the "ENTER" key for 2 seconds or longer, to switch to configuration mode –
ENTER "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 (dis-
playing 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 Pressing the "ESCAPE" key takes you one level higher in the menu structure.
ESCAPE
z + z Pressing the “ENTER“ and “ESCAPE“ keys simultaneously opens the configuration
ENTER ESCAPE menu.
The configuration menu is structured in levels. The first level contains main catego-
ries, 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.

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 Pa-

rameters":
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:
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 “Se-
tup“.
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 soft-
ware 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.
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.
4 HACD Operation
¾ Press the “UP” or “DOWN” keys to select “Inputs”.

9 The menu entry Analog Input 1 ("AI1") is shown.
¾ Press the “UP” or “DOWN” keys to select “Max. Value”.
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 “UP” until "." is displayed.
9 The parameter “Max. Value“ 10 Volts is now entered and displayed.
¾ Exit the Configuration Menu by pressing “ESCAPE" five times.
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.
¾ Press and hold the “ENTER“ and “ESCAPE” keys for at least 2 seconds until the
display reads “Setup“.
9 The card is at the second level of the Configuration Menu.
¾ Press the “UP” or “DOWN” keys to select “Display”.
9 Menu entry "Text" is displayed.
9 Press the “UP” or “DOWN” keys to select "OUT1".
9 The signal "OUT1" is displayed when the card returns to Run Mode.
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 During initial startup, BODAC software can be used to select the action of the control-
indication when an error occurs ler 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".
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 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.
Status Screen 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 Soft-
ware".
6 Detecting Errors
6 Detecting Errors
6.1 Error Messages
Error message Description
Reference voltage +10V (b32) or reference voltage –10V

+/- 10V voltage
(b30) outside allowable tolerances.
Supply voltage Ub (z30) outside allowable tolerances

Supply voltage
21...35V.
DO1~DO8 short circuit Short circuit on one or more of the 8 discrete outputs.
Checksum error in program or data memory (Flash or

Checksum
EEprom)
Memory error Error in working memory (RAM)
Versions of the individual program parts are not compatible

Version error
(can occur only if updates to firmware were made)
The signal on analog input AI1 is outside the valid signal

Analog Input AI1
range (adjustable, see Fig. 17 Menu tree "Faults").

Analog Input AI2

Analog Input AI3

Analog Input AI4

Analog Input AI5

Analog Input AI6
The block time value for a block has timed out, without
Block Timeout
another block being called.
SSI error Cable fault on SSI encoder
Block error Ambiguous block triggers
A control difference between setpoint (LC1) and feedback

LC1 <> LFB1 (LFB1). The difference value (window) and time delay (de-
lay) can be set in the controller card
A control difference between setpoint (LC2) and feedback

LC2 <> LFB2 (LFB1). The difference value (window) and time delay (de-
lay) can be set in the controller card
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 de-
scribed in section 2.4, GeneralCard Installation)
¾ Gently remove the fuse from the fuse holder (see Fig. 19).
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.
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
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
Index 7
I
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
© This document, as well as the

data, specifications and other
information set forth in it, are the ex-
clusive 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 giv-
en 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 RE 30146-B/08.07
Replaces: 11.06
Digital Controller for electro-hydraulic
Injection Molding Machines
Installation and Operation

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 DISPLAY/INPUT KEYS AND CONNECTORS ON THE FRONT PANEL............................................................................. 22
4.2 DIAGNOSTICS TEST JACKS ....................................................................................................................................... 23
4.3 MENU TREE FOR SETUP AND PARAMETERS ............................................................................................................. 23
4.4 DISPLAY/INPUT KEY OPERATIONS ........................................................................................................................... 28
5 DIAGNOSTICS............................................................................................................................................................. 33
5.1 DIAGNOSTIC OPTIONS ON THE HACD-DPQ CONTROLLER CARD ............................................................................ 33
5.2 DIAGNOSTICS USING BODAC ................................................................................................................................. 33
6 DETECTING ERRORS ............................................................................................................................................... 35
6.1 ERROR MESSAGES ................................................................................................................................................... 35
6.2 CHANGING FUSES ..................................................................................................................................................... 35
7 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.

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
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

1 General
Notes

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.

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 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-DPQ 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)
■ 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

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.

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
ATTENTION ATTENTION ACHTUNG
Static Sensitive Circuits sensibles à Elektrostatisch gefährdete
Devices l' électricité statique. Bauelemente.
Handle only at Manipulation uniquement Handhabung daher nur an

Static Safe Work autorisée sur un poste de geschützten Arbeitsplätzen
Stations travail protégé. erlaubt.
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.
______________________________________________________________

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.

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 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,
6 DI 3 Force Transfer Discrete log 0 = 0..2V,
8 DI 4 Inject/Jog + Discrete log 0 = 0..2V,
10 DI 5 Incremental Discrete log 0 = 0..2V,
Home 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,
16 DI 8 Analog Discrete log 0 = 0..2V,
Passthrough 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) Discrete Ub, 50mA,
output short-circuit protected
1)
24 nc
26 DO 2 Signal Fault Discrete Ub, 50mA,
output short-circuit protected
28 nc1)
30 Valve Output 1 Analog ± 10V, Rload min = 1k
output 0-20mA, Rload max = 500R
32 Valve Output 2 or Analog ± 10V, 10mA Rload min =
pressure feedback or output 1k
position feedback
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.

Row b Pin Description Type Specification

2 Cavity Analog input Differential input:
Pressure + ± 10V (Rin>100kΩ),
4 Cavity Analog input 0...20mA with Rin = 100Ω 3)
Pressure -
6 Pressure FB Analog input Differential input:
#1 + ± 10V (Rin>100kΩ),
8 Pressure FB Analog input 0...20mA with Rin = 100Ω 3)
#1-
10 Pressure Analog input Differential input:
Command + ± 10V (Rin>10MΩ),
12 Pressure Analog input 0...20mA with Rin = 100Ω 3)
Command -
14 Pressure FB Analog input Differential input:
#2+ ± 10V (Rin>100kΩ),
16 Pressure FB Analog input 0...20mA with Rin = 100Ω 3)
#2 -
18 Analog Cyl Analog input Differential input:
Pos Fdbk + ± 10V (Rin>100kΩ),
20 Analog Cyl Analog input 0...20mA with Rin = 100Ω 3)
Pos Fdbk -
22 Velocity Analog input Differential input:
Command + ± 10V (Rin>100kΩ),
24 Velocity Analog input 0...20mA with Rin = 100Ω 3)
Command -
26 Valve Output Analog output ± 10V, 10mA Rload min = 1k
3 or pressure
feedback or
position
feedback
28 AGND Analog GND 0V, reference for analog
outputs
30 REF- Reference - 10V, short-circuit protected,
voltage 30mA,
- 10V
32 REF+ Reference + 10 V, short-circuit
voltage protected, 30mA,
+ 10V
3)
= 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.

Row z Pin Description Type Specification

1)
2 nc
4 nc1)
6 nc1)
8 nc1)
10 Shield Shield internally connected with z
20
12 nc1)
14 nc1)
16 nc1)
18 nc1)
20 Ground System ground
22 DO 3 Back Discrete output Ub, 50mA, short-circuit
Pressure protected
24 DO 4 Inject Discrete output Ub, 50mA, short-circuit
Forward protected
26 DO 5 Decom Discrete output Ub, 50mA, short-circuit
Achieved protected
28 DO 6 At Shot Discrete output Ub, 50mA, short-circuit
Size protected
30 UB Supply voltage UB + 24V DC
UB(t) max + 35V DC
UB(t) min + 21V DC
32 LO Supply GND 0V
1)

Row f Pin Description Type Specification

2 DO 7 At Discrete output Ub, 50mA, short-circuit
Pressure protected
4 Clk + Clock output 5V Signal RS-485
SSI encoder compatible
6 Clk - Clock output 5V Signal RS-485
SSI encoder compatible
8 Data + Data input 5-24V Signal
SSI encoder
UA1 Incremental
encoder input
10 Data - Data input 5-24V Signal
SSI encoder
/UA1 Incremental
encoder input
12 UA2 Incremental 5-24V Signal
encoder input
14 /UA2 Incremental 5-24V Signal
encoder input
16 UA0 Incremental 5-24V Signal
encoder input
18 /UA0 Incremental 5-24V Signal
encoder input
20 nc1)
22 nc1)
24 nc1)
26 nc1)
28 CAN Gnd CAN Bus refence CAN Specification
30 CANL CAN Bus CAN Specification
input / output
32 CANH CAN Bus CAN Specification
input / output
1)

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)

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 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)
Software ■ 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.

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.

Notes

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 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.
Serial port The serial port on the front panel is configured as a standard RS-
232 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

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 "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”.

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 P max Limit 7 bar
(continued) xxxx.x [0~5000.0]
Fig. 5 Menu tree "Parameters Part 1"


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 Veloc. Limit 2 %
(continued) xxx.xx [+/-100.00]


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)


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]
Setup
with „ENTER + ESC“ Sprache / Language
to configuration English
menu Deutsch
Password
Off
On
xxxx [1~9/A~Z]
Fig. 9 Menu tree "Setup"

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 Pressing the "UP" key moves in the upward direction, within the
UP selected level, to available menu items. (for an overview, see
section 4.3: "Menu tree for settings and parameters")
z Pressing the "DOWN" key moves in the downward direction, within
DOWN the selected level, to available menu items (for an overview, see
section 4.3: "Menu tree for settings and parameters").
z Change menu mode:
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 is stored immediately in memory!
z Pressing the "ESCAPE" key takes you one level higher in the menu
ESCAPE structure.
z + z Pressing the “ENTER“ and “ESCAPE“ keys simultaneously opens
ENTER ESCAPE 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.

Fig. 10 Example of the menu levels in configuration mode
Changing from Run Mode to Configuration Mode – "EDIT

Parameters":
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:

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“.

Press “ESCAPE”.
9 The display will show scrolling text to display the manufacturer’s
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.
______________________________________________________________
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“.
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”.

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 “ENTER”.
Press “UP” until "." is displayed.
Press “ENTER”.
Press “ENTER”.
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.

Notes

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 During initial startup, BODAC software can be used to select the
indication when an error action of the controller when an error occurs (available in the
occurs “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.

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 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.
Status Screen 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 ".

6 Detecting Errors
6 Detecting Errors
6.1 Error Messages
Error message Description

Reference voltage +10V (b32) or reference voltage –10V
+/- 10V voltage
(b30) outside allowable tolerances.
Supply voltage Ub (z30) outside allowable tolerances
24 V Power
21...35V.
DO1~DO7 and
Short circuit on one or more of the 8 discrete outputs.
ENABLE short circuit
Checksum error in program or data memory (Flash or
Checksum Flash
EEprom)
Memory error Error in working memory (RAM)
Analog Input AI1 The signal on analog input AI1 is outside the valid signal
Pressure Command range (adjustable in Analog Config Screen in BODAC).
Pressure FB #1 range (adjustable in Analog Config Screen in BODAC).
Cavity Pressure range (adjustable in Analog Config Screen in BODAC).
Pressure FB #2 range (adjustable in Analog Config Screen in BODAC).
Analog Cyl Pos Fdbk range (adjustable in Analog Config Screen in BODAC).
Velocity Command 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
Profibus: The slave has left condition “DATA_EXCHANGE”
CANopen: The node has left the condition
Bus Fault
“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:
■ F / 4A / 250V

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

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.

6 Detecting Errors
Notes

7 Index
Overlap..........................................................26, 27
7 Index Residual speed..............................................26, 27
Parameter changing ...................................... 30
Password....................................................... 27
Power cables................................................. 10
Action symbol ..................................................5 Reference voltage ......................................... 15
Analog GND...................................................15 Result symbol.................................................. 5
Analog input...................................................15 Run mode...................................................... 29
BODAC setup routine ....................................19 Running text ............................................ 29, 30
BODAC software ...........................................19 Safety fuse .................................................... 35
Characters .......................................................5 Safety requirements ........................................ 4
compatible .....................................................14 Sensor lines................................................... 10
Configuration mode .......................................29 Serial port ...................................................... 22
Control card Setpoint parameter
Installation ...........................................................13 Acceleration.........................................................25
Control parameter Delay ...................................................................25
|CMD-LFB|< ........................................................25 Setpoint ...............................................................25
|CMD-LFB|> ........................................................25 Speed-.................................................................25
D 25 Speed+ ................................................................25
D (LFB1)..............................................................25 Shield ............................................................ 10
I 25 Shielding........................................................ 10
P 25 Sprache/Language ........................................ 27
T1 25 Supply GND .................................................. 16
Diagnostics terminal ................................23, 33 Supply voltage............................................... 16
Diagnostics using BODAC.............................33 Symbols........................................................... 5
Differential inputs ...........................................10 System ground .............................................. 10
Display ...........................................................22 Transport ....................................................... 12
DOWN ...........................................................28 Troubleshooting............................................. 11
Drives UP 28
Electromechanical and electrohydraulic ...............5 Warning symbol
EC Directive 89/392/EWG (Machine Directive)8 Equipment damage ...............................................6
Edge connector..............................................14 Hazard potential, electrical current........................5
EMC Regulations.............................................8 Hazard potential, general ......................................5
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
Parameters Part 1 ...............................................25
Parameters Part 2 ...............................................26
Parameters Part 3 ...............................................26
Parameters Part 4 ...............................................27
Setup ...................................................................27
Noise sources ................................................10
Output compensation

Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany

information set forth in it, are the ex-
clusive property of Bosch Rexroth
AG. It may not be reproduced or
given to third parties without its
consent.
our information. The information giv-
en 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 RE 30159-B/10.11
Replaces: 10.09
for hydraulic axes with
sercos interface English
Type VT-HNC100...3X/S...
Operating instructions
The data specified above only serve to de-
scribe the product. No statements concerning
a certain condition or suitability for a certain
application can be derived from our informa-
tion. 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, specifi-

cations 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 pre-

pared 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
5 Assembly........................................................................................................15
5.1 Unpacking................................................................................................15
5.2 Installation conditions..............................................................................15
5.3 Recommended accessories....................................................................15
5.4 Assembling the VT-HNC100...3X/S.........................................................16
6 Maintenance...................................................................................................18
6.1 Cleaning and care....................................................................................18
6.2 Repair......................................................................................................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
8 Disposal..........................................................................................................20
8.1 Environmental protection.........................................................................20
9 Troubleshooting.............................................................................................21
9.1 How to proceed for troubleshooting.........................................................21
10 Appendix.........................................................................................................22
10.1 Address 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 instruc-
tions” before working with the VT-HNC100...3X/S... digital axis control.
1.1 Issue 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 --
1.2 Related 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.
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 com-
plied 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 condi-
tion 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 person-
nel about the failures.
2.1 Intended use

The VT-HNC100...3X/S... is exclusively intended for being integrated in a ma-
chine 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 more-
over 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”.
2.2 Improper use

Any use of the VT-HNC100...3X/S... other than described in chapter 2.1 “Intended
use” is considered as improper.
2.3 Personnel qualification

Assembly, commissioning and operation, disassembly, service (including main-
tenance 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 pertain-
ing to the work to be done. Qualified personnel must observe the rules relevant to
the subject area.
2.4 Safety 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 /
Application
warning sign
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 disre-

garded, the operating procedure may be impaired.
2.5 Adhere 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 ma-
chine 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.
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 corre-
sponding 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
• 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).
• Troubleshoot system components as follows:

–– Switched inductivities DC: Antiparallel free-wheeling diode over actua-
tor 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. Commis-
sion 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.
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.
Product description
4 Product description
4.1 Pin assignments

VT-HNC100-C-3X/S-S-00/000, Material number R901112919
(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 X3C RS232
3 – Data – Data Pin

2 + Data + Data 1

1 EGND 2 TxD
3 RxD

4 reserved

5 GND

X2D DIO (Digital) 6 reserved
7 reserved
Pin
8 Shield
8 reserved
7 OUT2 9

6 OUT1
5 IN 4

4 IN 3

3 IN 2
X1S Power
2 IN 1
Pin
1 DGND
1 GND

2 GND

3 18 – 30 V

X2A AIO (Analog)

Pin

8 Shield
X7 sercos II
7 24 Vsens
S1 TX
6 Vout1 +
S2 RX
5 Vout2 +

4 Vin 1
3 Cin2 +
2 Cin1 +
1 AGND
Product description
VT-HNC100-1-3X/S-I-30/000, Material number R901234133

(1-axis version with sercos III and with interface optionally for incre-
mental, 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 posi-
tion transducer)
Slot 1 Encoder
X8M1
Incremental 1 Vpp EnDat 2.2 SSI Analog
Pin 1 – B (Inc) – B (Inc)
2 + CLK + CLK
3 + R (Inc) + R (Inc)
4 – R (Inc) – R (Inc)
5 + A (Inc) + A (Inc)
6 – A (Inc) – A (Inc)
7 – CLK – CLK
8 + B (Inc) + B (Inc)
9 – Data – Data
10 EGND EGND EGND EGND EGND
11 + Data + Data
X3C RS232 12 +5 Venc +5 Venc +5 Venc Slot 1 X2D1 DIO
Pin (Digital)
13 +10 Vref
1 14 +24 Pin 1 I/O 1
2 TxD Venc 2 I/O 2
3 RxD 15 Vimp1 3 I/O 3
4 reserved 4 I/O 4
5 GND 5 I/O 5
6 reserved 6 I/O 6
7 reserved 7 I/O 7
8 reserved 8 I/O 8

9 9 I/O 9
10 I/O 10

11 I/O 11

12 DGND
X1S Power
Pin
1 GND
Slot 1 X2A1 AIO
2 GND
(Analog)
3 18 – 30 V

Pin 1 Vin1 +

2 Vin1 –

3 Vin2 +

4 Vin2 –

X7E1, X7E2
5 Cin1 +

6 Cin1 –
sercos III
connection 7 Cin2 +

8 Cin2 –

9 reserved
10 AGND
11 Vout1 +
12 Vout2 +
13 Cout1
– The pins marked with “reserved” are reserved and must not be connected! 14 +24 Vsens
– PROFIBUS DP or CANopen (connection X7P/C) are not available with the sercos version. 15 reserved
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

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
Assembly
5 Assembly
5.1 Unpacking
Dispose of the packing in accordance with the national regulations in your country.
5.2 Installation conditions

For installing the product always observe the ambient conditions specified in
RE 30159.
5.3 Recommended 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, R901189300
for analog signals (connection X2A1) and digital
position transducers (connection X8M1) with
HD plug and open breakout cable for:
VT-HNC100-1-3X
Cable set VT17220-1X/HNC100-3X, length 2 m, R901189302
for analog signals (connection X2A) and digital
position transducers (connection X8M) with
FK MC plug and open breakout cable for:
VT-HNC100-C-3X
Assembly
5.4 Assembling 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 connec-
tion 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
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 as-
sembling 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 differ-
ences 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.
Maintenance
6 Maintenance
6.1 Cleaning 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.
6.2 Repair
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 ad-
dress specified in chapter 10.1.
Disassembly and replacement
7 Disassembly and replacement
7.1 Required tools

No tools required.
7.2 Preparing 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, depres-
surized 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 de-
energized.
7.3 Disassembling 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.
Pull out from below

Press Down by pressing on top
Fig. 5: VT-HNC100...3X/S... disassembly from the top hat rail

Disassembly and replacement / disposal
7.4 Preparing 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.
8 Disposal
8.1 Environmental 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!
Troubleshooting
9 Troubleshooting
9.1 How 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 in-
ability to restore the original error cause.
• First get a general idea of how the product works in conjunction with the en-
tire 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 direc-
tory in chapter 10.1.
Appendix
10 Appendix
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@boschrexroth.de
Contact person for service

Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str.8
97816 Lohr am Main
Germany
E-mail: service@boschrexroth.de
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
documentation@boschrexroth.de
www.boschrexroth.de
Subject to change without notice

Printed in Germany
RE 30159-B/10.11
History of the RE 30543-10-Z/04.12
Replaces: 02.11
VT-HACD-...-2X product family
User program BODAC and firmware

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 structure..................................................................................................... 14
4/20 Bosch Rexroth AG | Hydraulics History VT-HACD-2x product family | RE 30543-10-Z/04.12
3.3 New Features ............................................................................................ 16

General ...................................................................................................................... 16
Analog I/O .................................................................................................................. 16
Manufactury................................................................................................................ 16
Feedback encoder...................................................................................................... 16
Communication .......................................................................................................... 16
Tables ........................................................................................................................ 18
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.

Bodac
2 Bodac
2.1 Overview
Version Date Bugfixes New features
General General
Controller Manufactury
Bodac2.03.00.00 01.04.2012
parameters Feedback Encoder
Table Communication
Controller parameters
General General
Bodac2.02.01.00 23.02.2011
HACD-1x Family Communication
General
Bodac2.02.00.00 20.12.2010 Communication Communication
Table
Bodac2.01.00.00 21.04.2010 Start of production Start of production

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
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.
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
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
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
Bodac2.03.00.00
 Expand the parameter editor with the parameters „Stop CMD“ and “Limit I-
Control”
 Expand the parameter summary with the parameters “Stop CMD” and “Limit I-
Control”
Firmware HACD-2x
3 Firmware HACD-2x
3.1 Overview
Package solutions
Version Date Bugfixes New features
FWA-HACD-2x-FW0-20V06 Manufactury
FWA-HACD-2x-FWP-20V06 Feedback encoder
01.04.2012
FWA-HACD-2x-FWE-20V06 Communication
FWA-HACD-2x-FWN-20V06 Controller parameters
FWA-HACD-2x-FW0-20V04_0014
Communication General
FWA-HACD-2x-FWP-20V04_0014
29.11.2011 Controller parameters Communication
FWA-HACD-2x-FWE-20V04_0014
Controller structure Tables
FWA-HACD-2x-FWN-20V04_0014
General
18.10.2011 Internal Flags Analog I/O
Controller structure
22.07.2011 Manufactury
14.04.2011 Feedback encoder
Feedback encoder
01.03.2011 Communication
02.02.2011 Communication
FWA-HACD-2x-FW0-20V04
General
FWA-HACD-2x-FWP-20V04
20.12.2010 Communication Communication
FWA-HACD-2x-FWE-20V04
FWA-HACD-2x-FWN-20V04
FWA-HACD-2x-FWP-20V02 21.04.2010 Start of production Start of production
FWA-HACD-2x-FWE-20V02
Firmware HACD-2x
Package information
Version Hardware Contents Bodac Ethernet
bot.04.00.00
MER.04.00.00
FWA-HACD-2x-FWP-20V06 LW 0.6.3.0
21a Ixx.04.00.00 Bodac2.03.00.00
FWA-HACD-2x-FWE-20V06 FW 0.B.B.0
Pxx.04.00.00
FWA-HACD-2x-FWN-20V06
VAL.02.00.00
bot.03.03.00
FWA-HACD-2x-FW*-
20b MER.03.06.00
20V04_0014 / LW 0.6.3.0
/ Ixx.03.03.00 Bodac2.02.01.00
FWA-HACD-2x-FWN- FW 0.B.9.0
20a Pxx.03.01.00
20V04_0014
VAL.02.00.00
bot.03.02.00
FWA-HACD-2x-FW*-
20b MER.03.05.00
20V04_0012 / LW 0.5.1.0
/ INO.03.01.00/Ixx.03.02.00 Bodac2.02.01.00
FWA-HACD-2x-FWN- FW 0.A.1.0
20a Pxx.03.00.00
20V04_0012
VAL.02.00.00
bot.03.01.00
FWA-HACD-2x-FW*-
20b MER.03.04.00
20V04_0010 / LW 0.5.1.0
/ INO.03.01.00/Ixx.03.02.00 Bodac2.02.01.00
20a Pxx.03.00.00
20V04_0010
VAL.02.00.00
bot.03.00.00
FWA-HACD-2x-FW*-
20b MER.03.04.00
20V04_0008 / LW 0.5.1.0
/ INO.03.01.00/Ixx.03.02.00 Bodac2.02.01.00
20a Pxx.03.00.00
20V04_0008
VAL.02.00.00
bot.03.00.00
FWA-HACD-2x-FW*-
20b MER.03.03.00
20V04_0006 / LW 0.5.1.0
/ INO.03.01.00/Ixx.03.02.00 Bodac2.02.01.00
20a Pxx.03.00.00
20V04_0006
VAL.02.00.00
bot.03.00.00
FWA-HACD-2x-FW*-
20b MER.03.00.00
20V04_0004 / LW 0.5.1.0
/ Ixx.03.01.00 Bodac2.02.01.00
20a Pxx.03.00.00
20V04_0004
VAL.02.00.00
bot.03.00.00
FWA-HACD-2x-FW0-20V04 20b
MER.03.00.00
FWA-HACD-2x-FWP-20V04 20b LW 0.5.1.0
Ixx.03.00.00 Bodac2.02.00.00
FWA-HACD-2x-FWE-20V04 20b FW 0.A.1.0
Pxx.03.00.00
FWA-HACD-2x-FWN-20V04 20a
VAL.02.00.00
bot.02.01.00
MER.02.00.00
LW 0.4.A.0
FWA-HACD-2x-FW*-20V02 20b Ixx.02.00.00 Bodac2.01.00.00
FW 0.9.1.3
Pxx.02.00.00
VAL.02.00.00
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
 Calibration of current output AO1 will now be at 19 instead of 20mA
Feedback encoder
 Correct SSI-velocity value at enable low
 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
 Correct the internal flags after a block change
Communication
 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.
Firmware HACD-2x
 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”
 Bugfix for the bustransfer of active damping and output edit parameters
 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
 Correct the conversion of the HACD-1x parameters „s-ramp start“ and „s-
ramp end“ into the HACD-2x parameters „acceleration“ and „deceleration“
 Correct parameter interpretation of LS2/LS3 in the parameter editor
 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
 Remove Bus-Option as external dwelltime, because it’s not possible.
Firmware HACD-2x
 Sporadic peaks in the DT1(LFB) signal are fixed.
Firmware HACD-2x
3.3 New Features
General
 Put all firmware moduls to a firmware package together
 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
 Improve the quality of the analog input signals
Manufactury
 Implementation of an additional check, if an HACD-2x hardware has got the
corresponding HACD-2x software in it.
Feedback encoder
 Allow single-ended incremental encoder to be used, which is available with
hardware version 21a or newer
Communication
 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”
Firmware HACD-2x
 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)
 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
 Expand the parameter editor with the parameters „Stop CMD“ and „Limit I-
Control“
Firmware HACD-2x
Tables
 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)
Firmware HACD-2x
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany

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.
our information. The information
given does not release the user
from the obligation of own judg-
ment 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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Proportional directional valve, RE 29014/06.

Type STW 0195, type STW 0196

STW 0195: Size 6

STW 0196: Size 10

Table of contents Features

With integrated digital electronics and pQ functionality Further details

With integrated digital electronics and pQ functionality Further details in clear

Type Size Material no. Symbol

STW 0195-2X/1V5-24CF6 6 R900767353 A B

Structure, function, section

Qcomm Q open-loop control p closed-loop control

Functional section of STW 0195–2X

Hydraulic (measured with HLP 46 at ϑoil = 40 °C ± 5 °C and p = 100 bar)

1) Operating pressure, due to valve and sensor

Sensors STW 195 (size 6) and STW 196 (size 10)

Matching error Zero point < 0.15 % of final value

Electrical connections, pin assignment

Component plug pin assignment X1, 11-pin + PE to DIN EN 175201-804

Electrical connections, pin assignment

Pin Assignment Baud rate kbit/s 20 to 1000

Electrical connections, pin assignment

Block circuit diagram, integrated control electronics

11 Actual posi- Oscillator

Valve with inductive positi-

24V signal supply 9 DC +Ui

Characteristic curves of STW 0195-2X/1...

Transient function, STW 0195-2X/1..., A → T

100 0 - 100 100

Transient function, STW 0195-2X/1..., P → A

100 0 - 100 100

Characteristic curves of STW 0196-1X/1...

Transient function, STW 0196-1X/1..., A → T, B → T

100 0 - 100 100

Transient function, STW 0196-1X/1..., P → A

100 0 - 100 100

Characteristic curves of STW 0195-2X/1... and STW 0196-1X/1...

Frequency response, STW 0195-2X/1...

Frequency response, STW 0196-1X/1...

Characteristic curves of STW 0195-2X/1...

Flow characteristic curve A → T, ∆p = 5 bar Flow characteristic curve P → A, ∆p = 5 bar

Characteristic curves of STW 0195-2X/2...

Flow characteristic curve A → T, ∆p = 5 bar Flow characteristic curve P → A, ∆p = 5 bar

Characteristic curves of STW 0196-1X/1...

Performance limit B → T, closed-loop position controlled Flow characteristic curve A → T, ∆p = 5 bar

Flow characteristic curve P → A, ∆p = 5 bar Flow characteristic curve B → T, ∆p = 5 bar

Unit dimensions STW 0195-2X/1... (nominal dimensions in mm)

Unit dimensions STW 0196-1X/1... (nominal dimensions in mm)

ca.35 339 ”X”

Required surface quality of F1 P F2

Accessories (not included in the scope of supply)

The following is required for parameterisa- CANopen Profibus DP

Accessories, port X1(not included in the scope of supply)

Cable socket for X1

Accessories, CAN bus (A coding) (not included in the scope of supply)

Description Detail, dimensions Pin pattern, order information

Accessories, Profibus (B coding) (not included in the scope of supply)

Description Detail, diemnsions Pin pattern, order information

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

General information on maintenance and commissioning of hydraulic components

Characteristic curves of size 6 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)

Frequency response characteristic curves – spool symbol V

Flow/load function with max. valve aperture – spool symbol V

Characteristic curves of size 6 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)

Leakage flow with central spool position  – spool symbol V

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

16 l/min nominal flow at 10 bar valve pressure differential

32 l/min nominal flow at 10 bar valve pressure differential

Characteristic curves of size 10 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)

Characteristic curves of size 10 (measured with HLP46, ϑoil = 40 °C ±5 °C, ps = 10 bar)

Leakage flow with central spool position – spool symbol V

Characteristic curves of size10 (measured with HLP46, ϑoil = 40 °C ±5 °C, p = 100 bar)

125 P → A / B → T 2 Dp = 20 bar constant

Mating connector to DIN EN 175201-804