VT-HACD-1 - Digital Controller For Electromechanical and Electrohydraulic Drives

VT-HACD-1 – Digital controller RE 30143-B/04.
07
Replaces: 03.06
for electromechanical
and electrohydraulic drives
Installation and Operation

2/44 Bosch Rexroth AG | Hydraulics Installation and Operation | RE 30143-B/04.07
RE 30143-B/04.07 | Installation and Operation Hydraulics | Bosch Rexroth AG 3/44
Contents
1 General..........................................................................................................5
1.1 About this Manual ..........................................................................................5

Additional Docum entation........................................................................................................5
Characters and Symbols ..........................................................................................................6
1.2 Scope of Supply .............................................................................................6
1.3 Requirements.................................................................................................7
2 Installing the HACD .....................................................................................8
2.1 Safety Requirements .....................................................................................8

Proper Use.................................................................................................................................9
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
3 Startup of the HACD Controller Card......................................................17
3.1 Preparing for Use.........................................................................................17
3.2 Installing BODAC software ..........................................................................18

Installation Requirements.......................................................................................................18
BODAC Setup..........................................................................................................................18
3.3 Initial startup with BODAC ...........................................................................19
4 HACD Operation.........................................................................................20
4.1 Display/Input Keys and Connectors on the Front Panel .............................20

4.2 Diagnostics Test Jacks ................................................................................22
4.3 Menu Tree for Setup and Parameters.........................................................22
4.4 Display/Input Key Operations ......................................................................31
5 Diagnostics.................................................................................................36
5.1 Diagnostic Options on the HACD Controller Card ......................................36
5.2 Diagnostics Using BODAC ..........................................................................37
6 Detecting Errors.........................................................................................38
6.1 Error Messages............................................................................................38
6.2 Changing fuses ............................................................................................39
7 Index............................................................................................................41
General 1
1 General
1.1 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:
n avoid hazards and dangers

n minimize repair costs and downtime
n 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 Electrom e-
chanical and Electrohydraulic Drives".
It contains:
n RE sheet "RE 30 143" in paper form.

n Document RE 30 143-B: "Starting up the HACD Control Card and Operation of
the BODAC Software" (included with the shipment).
n Internet: www.boschrexroth.com
(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:
n Action symbol: The text following this symbol describes actions. These should be
performed, from top to bottom, in the given order.
n 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.
1.2 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:
n HACD Controller Card

n RE sheet RE 30 143
General 1
1.3 Requirements
Mounting the controller card in a 19” rack:
n VT 19 101
n VT 19 102
n VT 19 103
n VT 19 110.
described in datasheet RE 29 768, or mounted in a card holder
n 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:
n VT-NE30
described in datasheet RE 29 929.
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:
n The HACD Controller Card is not used properly.

(see page 9, Proper Use)
n The HACD Control Card is not installed, commissioned and operated by qualified
persons.
n Changes or modifications are made to the HACD controller card.
n 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.
Installing the HACD 2
Proper Use
The HACD controller card is designed for controlling electromechanical and electro-
hydraulic drives.
Applications include:
n open loop control

n closed loop position control
n closed loop speed control
n closed loop pressure and force control
n 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 perform ed 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:
n Use low-capacitance cables. Make cable connections without intermediate con-

nections whenever possible.
n Control electronics should be isolated from electromagnetic noise sources (IE:
V/F drives).
n Power wiring should not be routed in the vicinity of control electronics.
n Power wiring should not be routed in the vicinity of control wiring or cables.
n Route sensor lines separately.

n Maintain a distance of at least 1 meter from antenna lines, RF devices and radio
equipment.
n When using differential inputs switch both inputs on and off at the same time.
n When switching signal inputs, use dry circuit rated relays with gold-plated con-
tacts (low voltages, low currents)
n 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.
n 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.
n 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:
n Remove all power

n Ensure against unintended energization: lockout devices when possible, and use
lockout warning tags
n Verify that voltage is not present
n 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 ins ulated 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
AT TEN TION ATTEN TION A CH TU NG
Static Sensitiv e Circuits sensibles à Elektrostatisch gefährdete
D evic es l' électricité statique. Bauelemente.
H andle only at Manipulation uniquem ent H andhabung daher nur an

Static Safe W ork autorisée sur un poste de geschützten Arbeitsplätzen
Stations travail protégé. erlaubt.
H AC D _H W_ D E_ 2-1
Fig. 1 Notes for handling printed on the packaging
Observe the following:
n Keep the controller card away from moisture and dust

n 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:
Ø Remove power from the rack when installing the card.

Ø Hold the card by the front panel and remove it from the packaging.
Ø Slide the card into the guide rails of the rack without using excessive force, as
shown in Fig. 2 “Installing the control card”.
Ø 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
Ø Tighten the two mounting screws on the front panel.

ü 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 = 15..Ub

log 1 = 15..Ub

log 1 = 15..Ub

log 1 = 15..Ub

log 1 = 15..Ub

log 1 = 15..Ub

log 1 = 15..Ub

log 1 = 15..Ub
18 Enable Discrete input log 0 = 0..5V,

log 1 = 15..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 CANL-2 CAN Bus CAN specification

Input/Output
26 DO 2 Discrete output Ub-3V, 30mA,

short-circuit protected
28 CANH-2 CAN Bus CAN specification

Input/Output
30 AO 1 Analog output ± 10V, Rload min = 1k

0-20mA, Rload max = 500R
32 AO 2 Analog output ± 10V, 10mA Rload min = 1k

Tab. 1 Pin assignment Row d
Row b:
2 AI3+ Analog input Differential input

± 10V (Rin = >10MΩ),
4 AI3- Analog input 0...20mA with Rin = 100Ω
6 AI2+ Analog input Differential input:

± 10V (Rin>100kΩ),

± 10V (Rin>100kΩ),

± 10V (Rin>100kΩ),

± 10V (Rin>100kΩ),

± 10V (Rin>100kΩ),
26 AO 3 Analog output ± 10V, 10mA Rload min = 1k
28 AGND Analog GND 0V, reference for analog

outputs
30 REF- Reference voltage - 10V, short-circuit protected,

- 10V 30mA,
32 REF+ Reference voltage + 10 V, short-circuit pro-

+ 10V tected, 30mA,
Tab. 2 Pin assignment Row b
Row z
2 M1 + Solenoid a +
4 M1 - Solenoid a -
6 M2 + Solenoid b +
8 M2 - 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 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 Data + Data input 5-24V Signal

SSI encoder
10 Data - Data input 5-24V Signal

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 CAN_GND-1 CAN Bus reference CAN Specification
30 CANL-1 CAN Bus CAN Specification

input/output
32 CANH-1 CAN Bus CAN Specification

input/output
Tab. 4 Pin assignment Row f
Startup of the HACD Controller Card 3
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:
Ø Carefully check cabling.

Ø Apply power to the HACD controller card.
Fig. 3 Front panel of the HACD Controller Card
ü The controller card performs an internal function test.

ü The display on the controller card shows the manufacturer name and version
number in scrolling text (when powered up)
3 Startup of the HACD Controller Card
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:
n 200 MHz Pentium processor (or equivalent)

n 32 MB working memory (RAM)
n VGA graphics card, minimum resolution: 800x600 pixels
n Hard drive with minimum 2 MB available space
n CD-ROM drive
n Mouse
n Available serial port
n freie serielle Schnittstelle
Software n 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:
Ø Insert the CD-ROM and locate the file “Setup.exe“.

Ø Double-click on “Setup.exe“.
ü The setup program will load and display a start screen.
Ø To run Setup, follow the instructions on the screen.
ü BODAC software will then be installed.
Startup of the HACD Controller Card 3
3.3 Initial startup with BODAC
n 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.
n Before proceeding with the following steps, be sure that the following require-
ments have been met:
n Serial interface cable is available
n A serial port on the PC is available
n BODAC software is installed.
Proceed with the initial startup:
Ø Connect serial cable (S/N 0776897) to the connector on the HACD card.
Ø Plug serial cable into the serial port (COM) on the PC.
ü The HDAC card and PC are now connected.
Ø Start the BODAC software.
ü Perform the software-side startup as described in the “Starting up the HACD
Control Card and Operation of the BODAC Software” document.
4 HACD Operation
4 HACD Operation
4.1 Display/Input Keys and Connectors on the Front Panel
n 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 con-
nect the card to a PC.
n The following illustration shows an overview of the display, input keys and con-
nectors on the front panel.
Fig. 4 Display, input keys and connectors on the control card
Display n The display is four characters in length. Messages that exceed four characters
are displayed as a scrolling display.
n When parameters are displayed, the negative or positive sign is indicated by the
“+” and “-“ LEDs.
HACD Operation 4
LEDs for Discrete I/O n 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 pre-
sent on a discrete I/O, the associated LED will illuminate.
Serial Port n 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 con-
nect 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).
4 HACD Operation
Buttons n 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
n 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 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:
n Menu tree "Parameter Part 1"

n Menu tree "Setup"
n Menu tree "Valve Menu"
n Menu tree "Analog I/O Part 1"
n Menu tree "Analog I/O Part 2"
n Menu tree "Digital I/O“
n Menu tree "SSI Konfiguration“
n 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
Ebene 1 Ebene 2 Ebene 3 Ebene 4 Ebene 5 Ebene 6

Parameter
Mit "ENTER" Block 1~32
zum Menü
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. 5 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]
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
Mit „Enter“ und „ESC“ Language
Zum Konfig-Menü German
English
Bus Configure
CANOpen
DeviceNet
Fig. 8 Menu tree "Setup"
Valve Menu *
Mit „Enter“ und „ESC“ Off
Zum Konfig-Menü Direct
Valve o. l.
Valve c. l.
4WRE
NG6 - 2x
NG10 - 2x
Fig. 9 Menu tree "Valve Menu"

HACD Operation 4
Analog I/O
Mit „Enter“ und „ESC“ Inputs
Zum Konfig-Menü AI1
Type
+/-10 Volts
0~10 Volts
0~20 mA *
4~20 mA *
Range
+/-100 %
0~100 %
Min. Value
[-2.00~+22.00] mA
[-11.00~+11.00] V
Max. Value
[-2.00~+22.00] mA
[-11.00~+11.00] V
Min. Fault %
[-2.0~+22.0] mA
[-11.0~+11.0] V
Max. Fault %
[-2.0~+22.0] mA
[-11.0~+11.0] V
Max Unit
[0.0~+50000.0]
AI2 … …
AI3 … …
AI4 … …
AI5 … …
AI6 … …
Outputs
AO1
Range
+/-100 %
[0~+100] %
Type
+/-10 Volt
[0~+10] Volt
[0~+20] mA
[+4~+20] mA
X1
Range
+/-100 %
[0~+100] %
Fig. 10 Menu tree "Analog I/O Part 1"

4 HACD Operation
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%
[-50000.00~+50000.00]
Fig. 11 Menu tree "Analog I/O Part 2"
* only for VT-HACD-1-1x/v0/1-P-1

HACD Operation 4
Digitale I/O
Mit „Enter“ und „ESC“ Inputs
Zum Konfig-Menü Binary Mode
Off
On
Enable Set OK
Off
On
Outputs
DO1
Window
[-50000.00~+50000.00]
Debounce
[+0.01~+60.00] sec
DO2 … …
DO3 … …
DO4 … …
DO5 … …
DO6 … …
DO7 … …
Fig. 12 Menu tree "Digital I/O“
SSI Configure
Mit „Enter“ und „ESC“ Nb. of Bits
Zum Konfig-Menü [8~31]
Data Type
Binary
Gray
Resolution [ct/Unit]
[0~+10000]
Offset [Unit]
[-400000.00~+400000.00]
Fig. 13 Menu tree "SSI Konfiguration“

4 HACD Operation
Faults
Mit „Enter“ und „ESC“ Analog Inputs
Zum Konfig-Menü AI1
Off
Stop
Flag
AI2 …
AI3 …
AI4 …
AI5 …
AI6 …
Block Timeout
Flag
SSI Fault
Off
Stop
Flag
Block Fault
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. 14 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:
l 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
param eters")
l Pressing the "DOWN" key moves in the downward direction, within the selected level,
to available menu items (for an overview, see section 4.3: "Menu tree for settings
DOWN
and param eters").
Change menu mode:
l Press the "ENTER" key for 2 seconds or longer, to switch to configuration mode –
"EDIT Parameters".
ENTER
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).
l
ESCAPE Pressing the "ESCAPE" key takes you one level higher in the menu structure.
l + l 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. 15 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.
Ø 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”.
ü The controller card is now in "EDIT Parameter" mode.
Changing from Run Mode to Configuration Mode:
The card must be in run mode.
ü 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“.
Ø Press “ESCAPE”.
ü The display is scrolling “Setup“.
Ø Press “ESCAPE”.
ü 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. 10 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!!
Ø Press and hold the “Enter“ and “ESCAPE“ keys simultaneously for at least 2
seconds until the display reads “Setup“.
ü The card is now in Configuration Mode.
Ø Press the “UP” or “DOWN” keys to select “Analog I/O”.
Ø Press “ENTER”.
ü The card is now at the second level of the Configuration Menu, “Analog I/O“
mode.
4 HACD Operation
Ø Press the “UP” or “DOWN” keys to select “Inputs”.

ü The menu entry Analog Input 1 ("AI1") is shown.
Ø Press the “UP” or “DOWN” keys to select “Max. Value”.
ü The current value is shown.
Ø Press “UP”.
This creates a positive sign. Pressing „DOWN“ gives the value a negative sign.
Ø Press “UP” until "1" is displayed.

Ø Press “UP” until "." is displayed.
ü The parameter “Max. Value“ 10 Volts is now entered and displayed.
Ø 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. 8 Menu tree "Setup") will be used.
The card should be in Run Mode.
Ø Press and hold the “ENTER“ and “ESCAPE” keys for at least 2 seconds until the
display reads “Setup“.
ü The card is now in Configuration Mode.
ü The card is at the second level of the Configuration Menu.
Ø Press the “UP” or “DOWN” keys to select “Display”.
ü Menu entry "Text" is displayed.
ü Press the “UP” or “DOWN” keys to select "OUT1".
ü 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:
n X1, 10 Volts for test equipment having R i 〈 100 kς

n X2, 10 Volts for test equipment having R i 〈 100 kς
n 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. 10 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. 11 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
Short circuit on one or more of the 8 discrete outputs.
circuit
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 compati-
Version error ble (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. 14 Menu tree "Faults").
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
(delay) 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
(delay) 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:
Ø Remove HACD controller card the card holder (reverse of the procedure de-
scribed in section 2.4, GeneralCard Installation)
Ø Gently remove the fuse from the fuse holder (see Fig. 16).
6 Detecting Errors
HACD_HW_EN_6-2
Fig. 16 Fuse on the HACD Controller Card
Ø Use a suitable test device to check the fuse. (continuity test)

Ø If the fuse is defective, replace it with the same type.
Ø 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 ............................................................... 18
BODAC software....................................................................... 18
CAN Bus in-/output................................................................... 13
Change parameter.................................................................... 35
Characters .....................................................................................6
compatible.................................................................................. 13
Configuration mode................................................................... 33
Control card
Installation .............................................................................. 12
Diagnostics terminal............................................................22, 36
Diagnostics using BODAC ....................................................... 37
Differential inputs....................................................................... 10
Digital input................................................................................. 13
Display......................................................................................... 20
DOWN ......................................................................................... 31
Drives
Electromechanical and electrohydraulic...............................5
EC Directive 89/392/EWG (Machine Directive).......................8
Edge connector.......................................................................... 13
EMC Regulations..........................................................................8
ENTER........................................................................................ 31
Error conditions.......................................................................... 36
Error messages ......................................................................... 38
ESCAPE ..................................................................................... 31
Front panel................................................................................. 12
Fuse............................................................................................. 39
HACD .......................................................................................... 36
Initial startup............................................................................... 36
Installation......................................................................................9
Installation requirements.......................................................... 18
Keys ............................................................................................. 31
LED´s for digital in-/.outputs .................................................... 21
Menu tree
"Analog I/O Part 1"................................................................ 27
"Parameter Part 1"................................................................ 23
"Parameter Part 2"................................................................ 24
"Parameter Part 3"................................................................ 25
"Setup".................................................................................... 26
"Valve Menu"......................................................................... 26
“Digital I/O“ ............................................................................. 29
“Faults”.................................................................................... 30
“SSI Konfiguration”................................................................ 29
”Analog I/O Part 2” ................................................................ 28
Noise sources ...............................................................................9
Parameter changing.................................................................. 33
Password.................................................................................... 26
Power cables.................................................................................9
Reference voltage..................................................................... 14
Result symbol................................................................................6
Run mode ................................................................................... 32
Running text ..................................................................32, 33, 35
Safety fuse.................................................................................. 39
7 Index
Safety requirements .....................................................................5

Sensor lines................................................................................ 10
Serial port ................................................................................... 21
Shield........................................................................................... 10
Shielding ..................................................................................... 10
Sprache/Language.................................................................... 26
Supply GND ............................................................................... 15
Supply voltage ........................................................................... 15
Symbols .........................................................................................6
System ground........................................................................... 10
Transport..................................................................................... 11
Troubleshooting......................................................................... 10
UP................................................................................................ 31
Warning symbol
Equipment damage..................................................................6
Hazard potential, electrical current........................................6
Hazard potential, general........................................................6
I
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
info@boschrexroth.de
www.boschrexroth.com
© 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/04.07

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VT-HACD-1 – Digital controller RE 30143-B/04.

Installation and Operation

1.1 About this Manual ..........................................................................................5

1.2 Scope of Supply .............................................................................................6

2 Installing the HACD .....................................................................................8

2.1 Safety Requirements .....................................................................................8

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

3 Startup of the HACD Controller Card......................................................17

3.1 Preparing for Use.........................................................................................17

3.2 Installing BODAC software ..........................................................................18

3.3 Initial startup with BODAC ...........................................................................19

4.1 Display/Input Keys and Connectors on the Front Panel .............................20

4.2 Diagnostics Test Jacks ................................................................................22

4.3 Menu Tree for Setup and Parameters.........................................................22

4.4 Display/Input Key Operations ......................................................................31

5.1 Diagnostic Options on the HACD Controller Card ......................................36

5.2 Diagnostics Using BODAC ..........................................................................37

6.1 Error Messages............................................................................................38

6.2 Changing fuses ............................................................................................39

1.1 About this Manual

n avoid hazards and dangers

n RE sheet "RE 30 143" in paper form.

Characters and Symbols

The following characters and symbols are used in the manual:

General hazard potential

Electrical current hazard

1.2 Scope of Supply

Included in the shipment:

n HACD Controller Card

Mounting the controller card in a 19” rack:

2 Installing the HACD

2 Installing the HACD

2.1 Safety Requirements

n The HACD Controller Card is not used properly.

In European countries: EC Directive 89/392/EWG (Machine Directive)

In European countries: EC Directive 89/336/EWG (EMC Directive)

Installing the HACD 2

n open loop control

Personnel Selection and Qualification

Work on the electrical equipment must be performed only by qualified special-

Design Changes and Electrical Installation

Note the following recommendations on electrical installation:

n Use low-capacitance cables. Make cable connections without intermediate con-

2 Installing the HACD

n Route sensor lines separately.

2.2 Repair and Troubleshooting

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:

n Remove all power

Installing the HACD 2

2.3 Transport, Storage and Handling the Controller Card

H andle only at Manipulation uniquem ent H andhabung daher nur an

Fig. 1 Notes for handling printed on the packaging

Observe the following:

n Keep the controller card away from moisture and dust