Bosch rexroth CytroForce-M Operating Manual Download Page 2

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2021

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Summary of Contents for rexroth CytroForce-M

Page 1: ...Servo hydraulic actuator CytroForce M Operating Manual RE62270 B 01 21 ...

Page 2: ...pplications for industrial property rights Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract All rights are reserved with respect to the content of this documentation and the availability of the product 1d690e74316346200a347e886cad618f 1 en_US ...

Page 3: ...delivery 19 5 About this product 21 5 1 Product description 21 5 1 1 General 21 5 1 2 Types of design 21 5 1 3 Structure 21 5 1 4 Solution matrix 24 5 1 5 System Structure 25 5 1 6 Custom extension 25 5 1 7 Technology function PFC 26 5 1 8 Functional safety 27 5 2 Identification of the product 29 5 2 1 Nameplate of the servo hydraulic actuator 29 5 2 2 Nameplates of main components 31 5 3 Technica...

Page 4: ...rror management and event management 57 9 2 1 Error management 57 9 2 2 Event management 58 9 3 Diagnostic messages of the application 58 9 4 Field data acquisition FDA 59 10 Maintenance and repair 61 10 1 General 61 10 2 Cleaning and care 61 10 3 Maintenance and inspection schedule 62 10 4 Repair 65 10 5 Spare parts 65 10 6 Replacement of components 65 11 Demounting and removal 67 11 1 General 67...

Page 5: ...Safety instructions on page 11 before working with the product 1 2 Required and supplementary documentation The product must not be commissioned until you have been provided with the documentation marked with the book symbol and you have understood and observed it Title Document number Document type System documentation from the system manu facturer General informa tion on the com plete system Ord...

Page 6: ...7581 Operating instruc tions Rexroth IndraDrive Additional Components and Accessories R911306140 Project planning manual Maintenance kit for servo hydraulic actuators SY SHA R 62249 B Operating instruc tions Control cabinet Air Conditioning EMC Design IP Code Electrics IndraDrive Rexroth EFC Fv Sytronix R911344988 Project Planning Manual Motor cables and connections with IndraDrive R911401938 Cata...

Page 7: ...quences of actions or instructions are explained which bear the risk of personal injury or damage to property The hazard avoidance meas ures described must be observed Safety instructions are structured as follows WARNING Type and source of danger and consequences in the case of non observance Hazard avoidance measures Warning symbol draws attention to a hazard Signal word identifies the degree of...

Page 8: ...umentation Table 2 Abbreviations Designation Meaning IO Inputs outputs EN European Standard Ex Explosion protection FDA Field Data Aquisition FKM Führungskommunikation master communication GND Chassis Ground HW Hardware IEC International Electrotechnical Com mission IP Ingress Protection ISO International Organization for Stand ardization NC Normally closed NO Normally open L1 L2 L3 Phase conducto...

Page 9: ...9 85 Servo hydraulic actuator Representation of information Bosch Rexroth AG RE62270 B 01 21 Designation Meaning VAC Volt Alternating Current Vpp Peak peak value of a voltage source ...

Page 10: ...10 85 Servo hydraulic actuator Representation of information Bosch Rexroth AG RE62270 B 01 21 ...

Page 11: ...vo hydraulic actuator is intended for use in production machines The product is intended exclusively for professional use and not for private usage Intended use includes having read and understood this documentation com pletely and this chapter in particular for the safety functions described in Chapter 5 1 8 Functional safety on page 27 the servo hydraulic actuator may only be used in the version...

Page 12: ...n under the direction and supervision of an expert Experts are those who are able to 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 requirements per taining to the work to be undertaken An expert must observe the relevant spe cific professional rules and have the necess...

Page 13: ...regulations and standards of the application 2 6 Product specific safety instructions The following safety instructions apply to chapters 6 to 14 WARNING Exceedance of the maximum temperatures Using the servo hydraulic actuator outside the approved tempera ture ranges may lead to malfunction or increased surface temperatures Only use the servo hydraulic actuator within the specified ambient and hy...

Page 14: ...ical connection points of the com ponents while power is turned on WARNING Danger due to hydraulic fluid under pressure Danger of poisoning and risk of injury e g eye injuries skin lesions poisoning due to inhalation and ingestion Check the lines for wear and damage before any com missioning Use personal protective equipment e g safety gog gles protective gloves suitable workwear safety shoes etc ...

Page 15: ...s or hearing aids have to consult a doctor before entering such an area CAUTION Uncontrolled system behavior Risk of injury The failure of individual components can lead to malfunction of the assembly and therefore to unforeseeable behavior Immediately have defective components exchanged CAUTION Improperly laid lines and cables Risk of injury Lay cables and lines so that no one can stumble over th...

Page 16: ... and machines basically requires the implementation of a holistic IT security concept which is state of the art in terms of technology Accordingly Bosch Rexroth products and their properties must be considered as components of installations systems and machines for their holistic IT security concept Unless otherwise documented Bosch Rexroth products are designed for operation in local physically a...

Page 17: ...st the attachment parts of the servo hydraulic actuator Do not place put the servo hydraulic actuator onto attached parts Never use the servo hydraulic actuator to sit or step on Do not place put any objects on top of it NOTICE Foreign particles and dirt in the system Risk of damage wear and malfunctions due to ingress of dirt and foreign particles Contamination and metal particles may damage the ...

Page 18: ...Rexroth AG RE62270 B 01 21 NOTICE Mixing of hydraulic fluids Mixing of hydraulic fluids of different make or different types of the same make is not permitted Observe the notes given by the fluid manufacturers of the hydraulic fluids used ...

Page 19: ...chnology function PFC provided on microSD card Extended scope of delivery In the variant safety capable axis the scope of delivery of the servo hydraulic actuator is extended by additional safety components see also Chapter 5 1 8 Functional safety on page 27 For the exact scope of delivery of the servo hydraulic actuator ordered by you please refer to your order confirmation Check the scope of del...

Page 20: ...20 85 Servo hydraulic actuator Bosch Rexroth AG RE62270 B 01 21 ...

Page 21: ...ions they mainly differ in the cylinder connection and compactness CytroForce M Integrated is an axis on the basis of a 3D sand core casting to offer a compact design with optimum flow profile In this variant the cylinder is integrated in the block Various component placement options provide func tional and mechanical variance CytroForce M Split is executed as normal drilled block and can be suppl...

Page 22: ... B 01 21 Main components The following figures may differ from your individual axis depending on the selected configuration The split version is also offered as piped variant In this case the cylinder is not flanged optional Fig 1 Product description of CytroForce M Integrated ...

Page 23: ...roSD card is not shown on the figures Cylinder unit The cylinder unit of the servo hydraulic actuator translates flow and pressure into a linear movement with force The cylinder positions are sensed by the position measuring system fitted Motor pump group The motor pump group makes hydraulic power available in line with demand Manifold block The switching logic for the optional rapid force mode ch...

Page 24: ...service interface of the control and instrumentation technology level or directly to the drive con troller For a functional description parameter description and description of diag nostic messages of the drive controller please refer to the related Bosch Rexroth documentation see also Chapter 1 2 Required and supplementary documentation on page 5 Operating panel of the drive controller The drive ...

Page 25: ...ctuators are directly connected to the drive controller Command and actual values can be processed via common bus sys tems Fig 4 System structure 5 1 6 Custom extension A comprehensive portfolio of custom extensions is available for the servo hydraulic actuator Safety on board The safety modules HSZ01 HAT02 and Safe Motion S4 which can be perfectly integrated allow the economic implementation of s...

Page 26: ...ty function is to be selected purely discretely at the customer s end i e not via a safe field bus the scope of delivery additionally includes the safety zone module HSZ01 Connect the HSZ01 with the optional S4 card of the control section via two Safe Motion bus cables Safe Motion bus cables are available in various grades and lengths simple short variant RKB0061 and more robust longer variant RKB...

Page 27: ...th an optional S4 card for the drive integrated safety technology Safe Motion The scope of delivery is extended by a control unit for inductive loads HAT02 1 The servo hydraulic actuator is a safety related sub system within a safe machine The responsibility for furnishing proof of and certifying the safety functions of the complete machine lies with the machine manufacturer The characteristic saf...

Page 28: ...ed safe control unit s for inductive loads HAT02 1 The braking and holding system is initiated from for example the safety func tion Safe Stop 1 Safe Stop 1 SS1 Fig 6 Braking holding system n motor speed v traversing speed of axis s axis position tv safe deceleration time The safety function SS1 can be used to realize controlled stopping according to stop category 1 to EN 60204 1 After the safety ...

Page 29: ...rticular attention to a proper execution of shield connec tions The precondition for utilizing Safe Motion is described in detail in the appli cation manual Rexroth IndraDrive Integrated Safety Technology Safe Motion as of MPx 18 911338920 see Chapter 1 2 Required and supplementary documentation on page 5 These preconditions must strictly be fulfilled 5 2 Identification of the product 5 2 1 Namepl...

Page 30: ...ional 20 21 32 Weight 82 Ambient temperature during opera tion normal or special rating Ta optional 95 135 167 230 Position of the CytroForce M nameplate The following figure shows the respective position of the nameplate of the servo hydraulic actuator types CytroForce M Split and Integrated Fig 8 Position of nameplate 1 CytroForce M Integrated top 2 CytroForce M Split side central nameplate ...

Page 31: ...rawing 5 3 2 Electrical interfaces Communication In the standard version of the drive controller the control section is provided with a Multi Ethernet communication module With the Multi Ethernet communication module ET drive controllers can be integrated in various Ethernet field bus systems The following Ethernet field bus systems are available Sercos III EtherCAT EtherNet IP PROFINET IO Further...

Page 32: ...ded with an axial fan unit series MSK and MS2N or with a radial one with series MSK only The fan unit can be rated for operating voltages of 115 V 60 Hz and 230 V 50 Hz For further information on the electrical connection refer to the wiring diagram description of system structure and interfaces 5 3 3 Software interfaces In the firmware and technology function of the drive controller process and s...

Page 33: ... at the attachment lifting points provided for that purpose Always use several lifting points for handling the servo hydraulic actuator Please observe the following points for transporting Properties of the load e g weight center of gravity mounting and attach ment points Way of attaching or picking up the load The product may only be transported if the requirements listed in this chapter are obse...

Page 34: ...nce an increase in the ambient temperature causes the hydraulic pressure in the cylinder to rise Store the assemblies in packaging in order to protect them from dust and dirt Store the assemblies protected against impacts and sliding After the transport packaging was opened it must be closed properly again for storage Use the original packaging for storage Procedure after expiration of the maximum...

Page 35: ...age 68 Should you have any queries please contact Bosch Rexroth Service 6 Pack the assemblies air tight together with a desiccant in an anti corro sion foil 7 Store the assemblies protected against impacts For further conditions see Requirement on page 34 In each case please observe any applicable provisions and laws regarding the handling of substances hazardous to water or to health ...

Page 36: ...36 85 Servo hydraulic actuator Storage Bosch Rexroth AG RE62270 B 01 21 ...

Page 37: ...sufficient accessibility may make the installation or the exchange of components more difficult or impos sible Components e g safety related pipes cannot be properly mounted or might be damaged Make sure that the installation space is sufficient The dimensions of the servo hydraulic actuator can be found on the installation drawing At no time e g handling mounting must the servo hydraulic actuator...

Page 38: ...ith HMV01 02 HMS01 02 HMD01 HCS02 03 R911309636 Generally the drive controller produces an increased leakage current If the drive controller is to be operated with a residual current circuit breaker type B or type B should be used Otherwise spontaneous triggering may occur 7 3 3 Cable set Information on the installation conditions for the motor power and motor encoder cable is provided in Chapter ...

Page 39: ...ured position until it is fixedly mounted to the mounting face provided at the customer s end Be careful when installing the actuator NOTICE Improper mounting of the servo hydraulic actuator to the customer s equipment Damage to property Mount the servo hydraulic actuator so that the cyl inder piston rod which is connected to the custom er s equipment is aligned and that there is no axial offset P...

Page 40: ... instructions in this chapter The mounting faces have to be clean and free from contamination 2 Use suitable mounting screws The requirements for the mounting screws depend on the application and have to be verified and determined by the customer 3 Ensure that the mounting screws are tightened by applying the specified tightening torque Tighten the screws alternately crosswise using a suit able to...

Page 41: ...otective earthing conductor is not permanently connected to the points of the components provided for this purpose Disconnect the electrical components from the mains or from the voltage source before accessing parts with voltages exceeding 50 V Secure electrical com ponents against restarting After switching off you should generally wait for 30 minutes before you touch an electrical component in ...

Page 42: ...es to large temperature differences and extreme weather influences Always store cables in a dry place Always unroll cables completely Never use damaged cables e g by pressure clamping or crushing In case of damage shut the system down and replace the cables Check the connection cables at regular intervals for damage and exchange them if necessary Check the connections for the protective earthing c...

Page 43: ...n antenna effect Avoid unnecessary line lengths and shorten the cables If possible install cables as close as possible to grounded metal surfaces reference potential Grounded and closed cable channels or metal pipes are the ideal solution Avoid freely suspended lines and lines installed on plastic supports They act as receiving antennas immunity to interference and also as transmitting antennas in...

Page 44: ...ents are connected or wired improperly short circuits or severe damage to persons and property may result Connect the electrical components according to the wiring diagram Wiring and connection work may only be carried out by Bosch Rexroth or by authorized and qualified per sonnel Before starting to electrical cabling of the servo hydraulic actuator the fol lowing work must have been completed Mec...

Page 45: ... for commissioning are 1 Inspection of the mechanical and electrical installation and cabling work Visually inspect the servo hydraulic actuator as well as the connected operating equipment in the control cabinet for obvious visible defects Eliminate any defects found Check whether guards against direct touching of active parts are avail able and that the protective guards are not faulty in the ca...

Page 46: ...Servo hydraulic actuator completely connected and supplied Drive controller firmware MPx20VRS microSD card which is inserted in the card slot of the drive controller PFC software see commissioning instructions Rexroth Sytronix SvP 7020 PFC Variable Speed Positioning of Hydraulic Axes R 62313 FK Chapter 1 2 Required and supplementary documentation on page 5 Standard Ethernet cable PC with free Ethe...

Page 47: ...l commissioning of the servo hydraulic actuator the machine manu facturer has to check and confirm the factory settings of the integrated Safe Motion safety technology Before a machine may be placed on the market the manufacturer of the machine has to conduct a risk assessment in accordance with Machinery Direc tive 2006 42 EC in order to determine the hazards related to operation of the machine ...

Page 48: ...r see Chapter 1 2 Required and supplementary docu mentation on page 5 Standard Ethernet cable PC with free Ethernet port Current version of IndraWorks Ds IndraWorks Ds 14VRS or later Control module for inductive loads HAT02 If a complete parameter backup was made before the drive controller was replaced it can be read in to speed up the restoration of the configuration After having read the parame...

Page 49: ...he chapters listed below is exe cuted because after the acceptance described below the safety related functions may no longer be re configured and the acceptance has to be car ried out anew 8 4 2 Axis validation Within the framework of the axis validation a test is run to see whether motion sensing of Safe Motion encoders and scaling settings corresponds to the real movement of the mechanical axis...

Page 50: ...bal monitoring functions If global monitoring functions are activated they can be accepted according to the documentation mentioned above Please note that the monitoring functions refer to the externally connected safety capable linear encoder since it provides the feedback in the case of a hazardous situation of the servo hydraulic actuator The following checks must be carried out if the monitori...

Page 51: ...d or reactions to zone errors take place In this dialog it is possible to check whether the servo hydraulic actuator as configured generates a zone error or reacts to zone errors Signal control of outputs If the function of safe outputs is used the documentation mentioned above can be used for acceptance 8 4 4 Escalation Stopping of the servo hydraulic actuator in the last escalation level is carr...

Page 52: ...e servo hydraulic actuator in a defined mode e g rapid tra verse and make sure that the functional valves remain in this switching state even in the case of an emergency stop This can be effected for example by ensuring that process data can be provided for the rapid tra verse mode This prevents a switchover in the PFC software Equally the activation of the valves for rapid traverse has be ensured...

Page 53: ...vel as well as the maximum duration of the movement until standstill is decisive for the safety examination of the servo hydraulic actuator The values have to be determined by the customer with the help of the oscilloscope function The values can be entered in the table shown above Measuring signals P 0 3257 SMO Actual position value P 0 3262 SMO P 0 3262 SMO Selected operating state bit 1 or bit ...

Page 54: ...54 85 Servo hydraulic actuator Test sequence for validating the safety functions Bosch Rexroth AG RE62270 B 01 21 ...

Page 55: ...f the drive controller Monitoring of the braking resistor load Monitoring of the HW IO modules for error free function if HW IO modules are provided Monitoring of field bus communication for failure Axis monitoring functions Monitoring for over and underpressures chamber pressures only overpres sures accumulator pressure Monitoring for overtemperatures motor oil Monitoring for excessive following ...

Page 56: ... a servo hydraulic actuator in the field to be recorded The acquired data describe the load of the axis components in the field and simplify diagnostics and fault detection if servicing or repairs have to be carried out The data are stored on the local storage medium of the control system Further information on field data acquisition can be found in Chapter 9 4 Field data acquisition FDA on page 5...

Page 57: ...in and or the enable granted 9 2 Error management and event management 9 2 1 Error management In the error management of the servo hydraulic actuator warning and error events are assigned to stop categories according to the type and severity of the event System events which have been categorized in this way lead to the reac tions listed in the following table Table 5 Stop categories of the servo h...

Page 58: ...troller warning occurs the diagnostic message Exxxx is gen erated followed by a diagnostic text The self contained servo hydraulic linear axis keeps on working normally in this state Within the software this state is signaled with a message code and the warning output is set if configured Application error If an application error occurs diagnostic text number Dxxxx is generated fol lowed by a diag...

Page 59: ...xroth Sytronix SvP 7020 PFC Variable Speed Positioning of Hydraulic Axes R 62313 FK 62313 FK see Chapter 1 2 Required and supplementary documentation on page 5 9 4 Field data acquisition FDA The servo hydraulic actuator is provided with a field data acquisition feature which stores relevant data on the inserted microSD card This is no Condition Monitoring since no models are available for wear ser...

Page 60: ...60 85 Servo hydraulic actuator Field data acquisition FDA Bosch Rexroth AG RE62270 B 01 21 ...

Page 61: ...d by specifi cally trained personnel WARNING Systems that are still running Risk of injury The work steps described in this chapter may only be performed on shut down systems Before beginning work Make sure that the drive motor cannot be switched on Ensure that all force transmitting components and connections are electrically switched off and secured against restarting according to the manufac tu...

Page 62: ... property Wear may lead to malfunctions Carry out the prescribed maintenance work at the time intervals specified in the operating instructions Check regularly that equipotential bonding is always connected on the drive unit After having carried out any work on the drive unit check that equipotential bonding has been re con nected If used according to the intended purpose the servo hydraulic actua...

Page 63: ... cylinder seal X Service DC Replace valve seals X Service DC Replace solenoid coils X Service DC Replace safety valves X X Service DC Replace couplings X Service DC Replace accumulator X Service DC Replace pump X Service DC Change fluid X Service DC Check accumulator pressure X X Qualified personnel Check operating temperature X X Qualified personnel Filter element excessively clogged X X Service ...

Page 64: ...y please contact Bosch Rexroth Service Checking the accumulator pressure Checking the filter element for clog ging Inspection testing in case of repeated warning or error messages Table 7 Inspection testing in case of repeated warning or error messages What Remarks Checking the gas pressure of the accumulator Maintenance work my only be carried out by Bosch Rexroth or authorized qualified personne...

Page 65: ...the system is still under pressure and is permanently prestressed Observe the specifications of the system manufac turer and the system end user Do not disconnect line connections ports or compo nents as long as the servo hydraulic actuator is pres surized The hydraulic circuit may only be opened by specifi cally trained personnel Bosch Rexroth has an extensive service offer regarding repairs Shou...

Page 66: ...66 85 Servo hydraulic actuator Replacement of components Bosch Rexroth AG RE62270 B 01 21 ...

Page 67: ...er Do not disconnect line connections ports or compo nents as long as the servo hydraulic actuator is pres surized The hydraulic circuit may only be opened by specifi cally trained personnel WARNING An incompletely demounted drive unit may fall down An incompletely demounted drive unit may drop and cause serious injuries When demounting the drive unit secure it against falling down WARNING Dangero...

Page 68: ...ge 39 Ensure during all these steps that no dirt gets into the openings 11 4 Storage further use Proceed as described in Chapter 6 Transport and storage on page 33 11 5 Replacement of components Generally the servo hydraulic actuator must not be opened The hydraulic system must remain closed If components are defective and require the hydraulic system to be opened contact Bosch Rexroth Service In ...

Page 69: ...y components The components have to be sent carriage paid to the following address Bosch Rexroth AG Service Industriehydraulik Bürgermeister Dr Nebel Strasse 8 97816 Lohr am Main Germany Packaging Upon request reusable systems can be used for regular deliveries The mate rials for disposable packaging are mostly cardboard wood and expanded poly styrene They can be recycled without any problems For ...

Page 70: ...70 85 Servo hydraulic actuator Bosch Rexroth AG RE62270 B 01 21 ...

Page 71: ...ator Bosch Rexroth AG RE62270 B 01 21 13 Extension and modification WARNING Loss of warranty Personal injury and damage to prop erty Modifications exceeding the extent described in these operating instructions are not permitted ...

Page 72: ...72 85 Servo hydraulic actuator Bosch Rexroth AG RE62270 B 01 21 ...

Page 73: ...rther parameter backup has to be made A comparison with the parameter set stored last during operation simplifies troubleshooting and helps you to quickly restore the configuration 14 2 How to proceed for troubleshooting Troubleshooting may exclusively be carried out by Bosch Rexroth or by authorized and qualified personnel of a specialized company that was authorized by Bosch Rexroth Moreover tra...

Page 74: ... break time was reduced or time in force control extended Adapt cycle Low pressure warning of accumulator High external system leakage leakage of gas pressure accumu lator Localize leakage Contact Bosch Rexroth Service Defective component increased generation of noise Localize leakage Contact Bosch Rexroth Service Malfunction or destruction of electronic components Incorrect wiring Check the wirin...

Page 75: ...xroth AG RE62270 B 01 21 15 Technical data The technical data can be found in the installation drawing the data sheets of the servo hydraulic actuator and the documentations from Chapter 1 2 Required and supplementary documentation on page 5 ...

Page 76: ...76 85 Servo hydraulic actuator Bosch Rexroth AG RE62270 B 01 21 ...

Page 77: ...ion on service repair e g delivery addresses and training Service worldwide Outside Germany please first get in touch with your personal contact The hot line numbers can be found in the contact information on the Internet Required information We can provide fast and efficient assistance if you have the following informa tion at hand Detailed description of the fault and the circumstances Details o...

Page 78: ...78 85 Servo hydraulic actuator Declaration of incorporation Bosch Rexroth AG RE62270 B 01 21 16 2 Declaration of incorporation Fig 17 Declaration of incorporation 1 ...

Page 79: ...79 85 Servo hydraulic actuator Declaration of incorporation Bosch Rexroth AG RE62270 B 01 21 Fig 18 Declaration of incorporation 2 ...

Page 80: ...80 85 Servo hydraulic actuator Declaration of incorporation Bosch Rexroth AG RE62270 B 01 21 Fig 19 Declaration of incorporation 3 ...

Page 81: ...81 85 Servo hydraulic actuator Declaration of incorporation Bosch Rexroth AG RE62270 B 01 21 Fig 20 Declaration of incorporation 4 ...

Page 82: ...82 85 Servo hydraulic actuator Declaration of incorporation Bosch Rexroth AG RE62270 B 01 21 ...

Page 83: ... 37 Installation conditions 38 Installation orientation 38 Installing signal control and power cables 42 Intended use 11 M Machine acceptance 50 Maintenance and inspection schedule 62 Maintenance and repair 61 Mechanical interfaces 31 Mechanical mounting 39 O Obligations of the machine end user 15 Operation 55 Operational states 55 56 P Personal protective equipment 15 Preparing the installation 3...

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Page 85: ...Bosch Rexroth AG Drives and Controls Zum Eisengiesser 1 97816 Lohr am Main 49 9352 40 30 20 my support boschrexroth com www boschrexroth com RE62270 B RE62270 B ...

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