Bosch rexroth HS5E Instruction Manual Download Page 98 | Manualshive

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Bosch rexroth HS5E Instruction Manual Download Page 98

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/104

A4... with HS5E(V)(L) control system Series 1x and 30

| Troubleshooting

Bosch Rexroth AG, RE 92076-01-B/2021-04-22

Table 28: Malfunction table of HS5E control systems

Malfunction

Possible cause

Remedy

Humming noise in the pressure
control or pressure/flow
fluctuations

Air pocket around the sensor

Bleed control system, pump
(see 8, on page 63) and pipes completely

Problem with the cable shield

Connect shield to ground

Incorrect protective earth connection in the
control cabinet

Properly connect protective earth connector

No connection from M0 to L0

Connect M0 (XH4, pin 4) and L0
(XH4, pin 2) in the control cabinet

Unfavorable place of installation/mounting
technique for the pressure transducer

Change installation location (e.g. suspended
mounting, no Minimess line, no throttling
point between pump and pressure
transducer), see page 44

Improperly high gain of the actual pressure
controller

Reduce P-gain, see chapter 8.1.7.2 on
page 76

Screaming noise

Oil level in the reservoir too low; pump partly
aspires air

Top up oil

Pump draws in air

Change routing of the suction line

Suction line leaky

Seal suction line

Pump cavitates when pressure is reduced
Diagnosis: Measure, whether the pressure in the
pressure line overshoots

Optimize controller, reduce the command
value via a ramp or in steps

Fluid in the reservoir is mixed with air; cooling
and/or filtration circuit leaky

sealing

Other unusual noise

Drive speed too high

Machine or system manufacturer

Wrong direction of rotation

Machine or system manufacturer

Inadequate suction conditions, e.g. air in the
suction line, insufficient diameter of the suction
line, viscosity of the hydraulic fluid too high,
suction height too high, suction pressure too low,
foreign particles in the suction line

Check whether shut-off valves are open

Machine or system manufacturer
(e.g. optimize inlet conditions, use suitable
hydraulic fluid)
Completely air bleed the control system, fill
suction line with hydraulic fluid
Remove foreign particles from the suction
line

Incorrect mounting of the control system

Check mounting of the control system
according to the specifications of the
machine or system manufacturer. Observe
tightening torques

Incorrect mounting of the assembled parts,
e.g. coupling and hydraulic lines

Fasten assembled parts according to the
parameters provided by the coupling fitting
manufacturer

Air in the pump or in the preload valve

Bleed pump and preload valve

Wear/mechanical damage to the control system Replace the control system, contact Rexroth

Service

No or insufficient pressure
(< 4 bar)

Faulty mechanical drive (e.g. defective coupling) Machine or system manufacturer

Hydraulic fluid not in optimal viscosity range

Use suitable hydraulic fluid (machine or
system manufacturer)

Output unit defective (e.g. hydraulic motor or
cylinder)

Machine or system manufacturer

Wear/mechanical damage

Replace the control system, contact Rexroth
Service

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Summary of Contents for rexroth HS5E

Page 1: ...Instruction manual RE 92076 01 B 2021 04 22 replaces 10 2017 DE Control system HS5E V L for Axial piston variable pump A4VSO A4VBO A4VSG and A4CSG ...

Page 2: ...nts concerning a certain condition or suitability for a certain application can be derived from our information The information given does not release the user from the obligation of own judgment and verification It must be remembered that our products are subject to a natural process of wear and aging The cover shows an example application The product delivered may differ from the image on the co...

Page 3: ...oduct description 22 5 2 1 Axial piston unit layout 22 5 2 2 Functional description HS5E L 23 5 2 3 Functional description HS5EV 23 5 3 Parallel and cascade control of the HS5E V L control system 24 5 3 1 Parallel control structure 25 5 3 2 Cascading control structure 26 5 3 3 Controller parameters parallel 27 5 3 4 Control parameter sets 27 5 3 5 Special operating modes 27 5 3 6 Working pressure ...

Page 4: ...7 7 6 1 Cable sets 57 7 6 2 Wiring the electronic components 57 7 6 3 Connection to the swivel angle sensor 58 7 6 4 X2M1 and X2M2 Analog configurable pressure sensor interface coding A M12 5 pin socket 58 7 6 5 X7E1 and X7E2 Plug in connector assignment for Ethernet interface coding D M12 4 pin socket 59 7 6 6 LED status indicators 59 7 6 7 Voltage supply of the HS5E pilot control valve 60 7 6 8 ...

Page 5: ...cement 90 11 1 Required tools 90 11 2 Preparing for removal 90 11 3 Performing the removal 90 11 4 Preparing the components for storage or further use 90 12 Disposal 91 13 Extension and conversion 91 14 Troubleshooting 92 14 1 How to proceed for troubleshooting 92 14 2 Error diagnosis memory 93 14 2 1 Fault diagnosis 93 14 3 Malfunction table 94 14 3 1 Swivel angle measurement check 100 15 Technic...

Page 6: ...you and you have understood and observed it Table 1 Required and supplementary documentation Title Document number Document type Order confirmation Contains the order related technical data for your axial piston variable pump A4 with HS5E V L control system Order confirmation Installation drawing Contains the outer dimensions all ports and the hydraulic circuit diagram for your axial piston variab...

Page 7: ...nd preservation 90312 Data sheet Rexroth HydraulicDrive functions firmware and software descriptions 30338 FK Functional description Rexroth HydraulicDrive functions firmware and software descriptions Additional information 30237 Z Functional description Rexroth HydraulicDrive functions Parameter description 30330 PA Parameter description Rexroth HydraulicDrive functions Description of diagnosis 3...

Page 8: ...ng sign signal word Meaning DANGER Identifies a dangerous situation that will result in death or serious injury if it is not avoided WARNING Identifies a dangerous situation that may result in death or serious injury if it is not avoided CAUTION Identifies a dangerous situation that may result in minor to moderate injury if it is not avoided NOTICE Property damage The product or surrounding area m...

Page 9: ...VBO and A4VSG A4CSG the designation Axial piston unit will be used in the following 1 3 4 Abbreviations This documentation uses the following abbreviations Table 5 Abbreviations Abbreviation Meaning ATEX EC directive on explosion protection Atmosphère explosible DB Pressure relief valve PT Pressure Transducer EMC Electromagnetic compatibility GND Ground n c not connected p Pressure character in fo...

Page 10: ...ing use The pressure flow control system is used for the electro hydraulic pressure and swivel angle control and torque limitation of an axial piston variable pump type A4VSO A4VBO A4VSG or A4CSG Observe the technical data the application and operating conditions and the performance limits according to the data sheets listed on page 6 and the order confirmations The HS5E V L control system is a pi...

Page 11: ...ent application If you need information about EMC compliant installation refer to Bosch Rexroth s EMC test documentation see data sheet 92076 Ensuring compliance with the limit values required by national regulations is the responsibility of the manufacturer of the system or machine European countries EC directive 2014 30 EU EMC Directive USA See the national electrical system regulations NEC Nati...

Page 12: ... use genuine Rexroth accessories and spare parts to ensure there is no hazard to persons from unsuitable spare parts Observe the technical data and ambient conditions specified in the product documentation If unsuitable products are installed or used in applications that are of relevance to safety unexpected operating conditions may occur in the application which could result in personal injury or...

Page 13: ...pressure control using a pressure sensor that is not parameterized in the electronic system parameterizing the electronics parameters incorrectly or setting the wrong command values Changes to the factory settings may only be made by Bosch Rexroth specialists In addition a pressure relief valve is required in the hydraulic system as back up If the axial piston unit is equipped with a pressure cut ...

Page 14: ... be pressurized even after separation from the actual pressure supply Do not disconnect any line connections ports or components as long as the hydraulic system is under pressure Escaping hydraulic fluid mist Risk of explosion and fire hazard health hazard risk of environmental pollution Depressurize the relevant machine system component and repair the leak Only perform welding work when the machi...

Page 15: ...ion e g impure hydraulic fluid abrasion or residual dirt from components As a result the hydraulic fluid flow and the build up of torque in the axial piston unit can no longer respond correctly to the operator s specifications Even the use of various filter elements external or internal flow filtration will not rule out a fault but merely reduce the risk Check whether your application requires rem...

Page 16: ...suitable working clothes safety shoes Immediately seek medical attention however if hydraulic fluid gets into your eyes or blood circuit or if you swallow it accidentally Danger from improper handling Slip hazard Risk of slipping on wet surfaces when climbing on the axial piston unit Never grab or climb onto the axial piston unit Check how to safely get on top of the machine system Missing potenti...

Page 17: ...closed circuit A4CSG Uncontrolled movements in the system In case of energy fluctuations and or failure the unit will move to Vg max α 100 depending on the available and sufficient load pressure and boost pressure system related Check whether additional measures are necessary on your machine for the application in order to guarantee that the torque is switched off If necessary make sure these are ...

Page 18: ...ation Product can be damaged or destroyed Never operate the axial piston unit with insufficient hydraulic fluid Specifically make sure that the rotary group has sufficient lubrication When commissioning a machine system make sure that the housing area and the working lines of the axial piston unit are filled with hydraulic fluid and remain filled during operation Avoid air inclusions in the forwar...

Page 19: ...ss Before commissioning ensure that all hydraulic connections are tight and that all seals and plugs of the plug in connection are correctly installed and undamaged to prevent fluids and foreign particles from entering the product Filter the hydraulic fluid when filling the system with a suitable filter system to minimize the solid particle contamination and water in the hydraulic system and to ac...

Page 20: ...ontamination of ground water Always place a drip tray under the axial piston unit when filling and draining hydraulic fluid Use a suitable binding agent to collect any leaked hydraulic fluid Observe the parameters in the safety data sheet for the hydraulic fluid and the specifications provided by the machine system manufacturer Danger from hot components Nearby products can be damaged Due to a hea...

Page 21: ...xial piston unit HS5E V L P control system according to order confirmation The following parts come assembled on the unit Transport protection of the drive shaft with keyed shafts 1 Protective covers 2 Protective plug threaded plug 3 For version with optional through drive U99 plugged with pressure tight cover 4 HS5E pilot control valve 5 Swivel angle sensor 6 Pressure transducer 1x with open circ...

Page 22: ... and the HS5EV control system only for the open circuit The flow is proportional to the drive speed and the displacement The flow can be smoothly changed by adjusting the swashplate In the open circuit the hydraulic fluid flows from the reservoir to the variable pump and is transported from there to the consumer via a directional valve From the consumer the hydraulic fluid flows back to the reserv...

Page 23: ...alue is equal to the torque actual value or the pressure command value is equal to the actual pressure value the valve s control spool is in the central position If the higher level controllers request an increase in the swivel angle for example which corresponds to an increase in the flow the system must keep deflecting the valve spool from the central position until the swivel angle has reached ...

Page 24: ...oportional valve 1 Information about HS5EV control With a de energized proportional valve and available load pressure 20 bar the pump swivels in the following cases Standard version A4VSO and A4VBO to swivel angle α 100 5 3 Parallel and cascade control of the HS5E V L control system The pump controller has two different control structures It is possible to switch between them using pump controller...

Page 25: ...lue processing before it is passed on to the actual swivel angle controller For pump control the pressure and swivel angle controllers are active at the same time and both generate a manipulated variable In the pump switching logic the system passes on as standard the lowest manipulated variable from these two controllers minimum value former function Using this minimum value former ensures that o...

Page 26: ...he switching logic the system forms the swivel angle command value that is valid for control In actual pressure value acquisition the system compares the different actual pressure values and generates from them the resulting sign for the switching logic The output of the swivel angle controller is passed on to the manipulated variable adjustment of the swivel angle controller P 0 2992 P 0 2914 P 0...

Page 27: ...arameter number Pressure controller P gain 2 positive P 0 2965 Pressure controller P gain 2 negative P 0 2966 Pressure controller deviation positive threshold P 0 2967 Pressure controller deviation negative threshold P 0 2968 5 3 4 Control parameter sets For the HS5E V L you have the option of configuring and using up to four different parameter sets Using these parameter sets it is possible to op...

Page 28: ...a the ports R2 to R7 If the hardware enable is canceled the output stage of the electronics is de energized With a de energized proportional valve and an existing load pressure 20 bar the pump swivels in the following cases Standard version A4VSO and A4VBO to swivel angle in direction α 100 After reduction of the load pressure an equilibrium of 10 bar will settle If no load pressure is available t...

Page 29: ...the maximum and minimum pressures in data sheet 92076 In the case of energy fluctuations or failures with adequate control pressure supply the unit moves to the minimum swivel angle possible standard version A4VSO and A4VBO to swivel angle α 0 Vg min and standard version A4VSG and A4CSG to swivel angle α 100 Limiting the minimum displacement can cause torque to be generated in the application Chec...

Page 30: ...he boost pressure With a sufficient load pressure 20 bar the control can take control positions in the swivel angle range of 100 to 100 for A4CSG With a de energized proportional valve and available load pressure 20 bar the pump swivels in the following cases Standard version A4CSG to swivel angle α 100 Vg min This can lead to cavitation and damage to the pump You can find the maximum and minimum ...

Page 31: ...the use of hydraulic fluids according to DIN 51524 HL HLP Adhere to all limits specified in the data sheet regarding temperature viscosity cleanliness of the hydraulic fluid 5 5 2 1 HFC fluids You are only allowed to use HFC with the basic pump with option F see type code of data sheet 92050 In the case of an application with HFC fluid be aware that the service life of the HS5E V L control system ...

Page 32: ...r Elastic pipe feedthrough Damping rails below the motor Installing the pump at an adequate distance from the container wall 5 6 2 Pulsation damper With some special applications we recommend using a pulsation damper for operation Due to the reduction in the pressure pulsation that is typical of pumps this also positively affects the noise level of the hydraulic system You can find information abo...

Page 33: ...tional description of the firmware P U XH4 XH4 1 UB 2 L0 4 M0 5 αset αactual 6 7 pset 10 pactual high 11 pactual low Master αset I pset I UR 0 V 1 UB 2 L0 4 M0 5 αset 7 pset 10 pactual high 11 pactual low Slave Fig 6 Example HS5E V L circuitry for master slave operation analog Fig 7 Example of HS5E V L for analog master slave operation and independent individual operation alternatives possible P U...

Page 34: ...l via a second channel of coupling element K1 in master slave mode Make sure that the P and D controller parameters on the slave are not set higher than on the master Slave units can be calibrated by means of the corresponding calibration cycle 5 7 1 1 Switching over to analog master slave mode The 0 V reference potential of the PLC command value source and M0 L0 of the HS5E pilot control valve mu...

Page 35: ...compatible PC with a Pentium IV processor at least CPU clock frequency 2 GHz Main memory 4 GB 5 GB of free hard disk space on drive C incl temporary memory during installation A DVD drive when installing from DVD Graphics resolution 800x600 pixels 16 bit color depth Indraworks Engineering is designed for a default screen setting of 96 dpi If you use any other settings this can lead to screen eleme...

Page 36: ... delivered ex works with the current firmware Older firmware versions on request 5 9 Switch on sequence of electronics hydraulics Due to the different monitoring routines that are integrated on the electronics assemblies the system can issue fault messages in the case of adverse switch on sequences These fault messages lead to uncertainty even though there is no real reason for them Be aware of th...

Page 37: ...45678 xxxxxxxxxxxx MNR FD Rexroth A4VSO180HS5EV 30RPZB13N00 19W10 1 5 2 3 4 9 10 11 12 6 7 8 13 14 Fig 8 Sample name plate A4VSO HS5EV control system 1 Manufacturer 2 Manufacturing date 3 Internal plant designation 4 Direction of rotation viewed on drive shaft here clockwise 5 Bar code 6 Power setting optional 7 Rotational speed 8 Flow setting optional 9 Pressure controller setting optional 10 Max...

Page 38: ...essary Height mm Depth mm Weight may vary by equipment 6 1 1 Transport with lifting devices For transporting the axial piston unit can be connected to a lifting device via an eye bolt in the drive shaft or in the housing Alternatively it can also be transported with a lifting strap Only use the lifting strap if you are unable to achieve the required installation position with transport using the e...

Page 39: ...sible lifting strap Make sure that the axial piston unit is securely fixed with the lifting strap Only guide the axial piston unit by hand for fine positioning and to avoid swinging Never stand or reach under suspended loads Place the lifting strap around the axial piston unit so that it does not pass over assembled parts e g valves electrical assembled parts and sensors red arrows see Fig 10 and ...

Page 40: ... maximum permissible storage times for an originally packed axial piston unit as per data sheet 90312 Table 10 Storage time with factory corrosion protection Storage conditions Standard corrosion protection Long term corrosion protection optional Closed dry room uniform temperature between 5 C and 20 C Undamaged and closed corrosion protection film Maximum 12 months Maximum 24 months The entitleme...

Page 41: ... chapter 10 1 Cleaning and care on page 85 2 Drain the axial piston unit 3 For storage times up to 12 months Moisten the inside of the axial piston unit with mineral oil and fill with approx 100 ml mineral oil For storage times up to 24 months Fill the axial piston unit with VCI 329 corrosion protection 20 ml Filling is carried out via the drain port see chapter 7 4 Installing the axial piston uni...

Page 42: ...round with sufficient load bearing capacity Only open the packaging from the top Remove the packaging from the axial piston unit Check the axial piston unit for transport damage and completeness see chapter 4 Scope of delivery on page 21 Dispose of the packaging in accordance with the regulations in your country 7 2 Installation conditions The installation position and location of the axial piston...

Page 43: ...ut charge pump and or 0 7 bar abs with charge pump is present at port S during operation and at cold start in all installation positions and installation locations for the axial piston pump see Fig 11 See data sheet for other pressure values 0 2 0 8 abs 1 2 3 0 0 1 2 1 2 1 S Einschraubloch M22 M10 x1 5 M16 x2 M16 x2 M16 x2 M16 x2 M8 x1 25 Fig 11 Suction pressure 1 Absolute pressure gauge 2 Standar...

Page 44: ...rsion depth 200 mm S Suction port hmin Minimum required distance to reservoir bottom 100 mm SB Baffle baffle plate Table 11 Below reservoir installation Installation position Air bleed Filling 1 drive shaft horizontal R L R L 2 drive shaft horizontal T T 3 drive shaft vertically down T T 7 3 2 Above reservoir installation Above reservoir installation means that the axial piston unit is installed a...

Page 45: ...tect the axial piston unit from draining 25 mm S Suction port hS max Maximum permissible suction height 800 mm SB Baffle baffle plate ht min Minimum required immersion depth 200 mm Port F is part of the external piping and must be provided on the customer side to simplify the filling and air bleeding Table 12 Above reservoir installation Installation position Air bleed Filling 4 drive shaft horizo...

Page 46: ...f the ports and circuit diagrams If necessary an installation drawing can be requested Also observe the manuals provided by the manufacturers of the other hydraulic components when selecting the required tools 7 4 3 General instructions Follow these general notices when installing the axial piston unit Note that certain installation positions will affect the control system Gravity dead weight and ...

Page 47: ...rom improper handling Product can be damaged Do not assemble the coupling hub on the drive shaft of the axial piston unit by striking it 1 Assemble the specified coupling half on the drive shaft of the axial piston unit according to the instructions of the coupling manufacturer The drive shaft of the axial piston unit is equipped with a female thread Use this female thread to pull the coupling ele...

Page 48: ...support the gear wheel at the gearbox output separately 7 4 6 Installation with cardan shaft The following describes how to connect the axial piston unit to the drive motor with a cardan shaft Notice Damage to the axial piston unit and leaks at the shaft seal Improperly installed cardan shafts generate unbalances This results in vibrations and excessive forces on the drive shaft Observe the cardan...

Page 49: ...nal surfaces If sealing or functional surfaces are damaged contact your Bosch Rexroth service partner or the service department of the manufacturer s plant of the axial piston unit 2 1 3 Fig 15 Removing transport protection Example A4VSO with HS5E control system 1 Protective cover 2 Protective plug 3 For version with a through drive metallic protective cover and mounting bolts Ports intended for c...

Page 50: ... pmax see Table 13 Ports A4 Series 1x and 30 on page 53 The machine system manufacturer is required to ensure that the connecting elements and lines correspond to the specified application conditions pressure flow hydraulic fluid temperature with the necessary safety factors Connect only hydraulic lines that are match the axial piston unit port pressure level size system of units Observe the follo...

Page 51: ...al Standard Various kinds of seals are also used The system of units the kind of seal and the size of female thread and stud ends e g threaded plug must all match There is a risk of confusion due to the limited ways of visually telling them apart WARNING Leaky and bursting stud ends For fittings if a stud end that does not match the system of units kind of seal and size of the female thread is pre...

Page 52: ...rotation Fig 18 Example A4VSG 125 to 355 30 with HS5E pilot control valve clockwise rotation Fig 19 Example A4CSG 500 30 with HS5EP control system clockwise rotation Ports for A4CSG with HS5EL on request S T K2 K1 R L U B M2 M1 MS B1 Port overview A4VSG T K3 B A E R2 R4 RKV SP K2 R L U R5 R7 M2 M1 P MB MA S A T K3 MS K2 K1 R L U B E1 E2 E3 ME3 MABP MA M2 RKV M1 P Port overview A4CSG ...

Page 53: ...Control pressure port of accumulator port 350 X E Boost pressure supply 50 O E3 Boost pressure supply 40 O ME3 Measuring boost pressure supply 40 O E1 Filter supply 40 X E2 Filter return 40 X RKV Control fluid return flow 5 X K4 Accumulator port 40 X R2 R7 Air bleeding the stroking chamber 350 X XA XB Pilot pressure measuring 350 O 1 The measuring system and thread size can be found in the data sh...

Page 54: ...ckwise rotation Table 14 Example A4VSO sizes 40 to 1000 1 Proportional solenoid 2 Inductive position transducer for valve position 3 X8A actual swivel angle input 4 Reserved X2N 5 Configurable sensor interface X2M2 pressure sensor input 6 Configurable sensor interface X2M1 pressure sensor input 7 Multi EtherNet interface X7E1 8 Multi EtherNet interface X7E2 9 Plug in connector XH4 10 VT SWA LIN Sw...

Page 55: ...orque of female threads MG max Required tightening torque of threaded plugs MV WAF hexagon socket of the threaded plug Standard Thread size DIN 3852 M8 1 10 Nm 7 Nm1 3 mm M10 1 30 Nm 15 Nm2 5 mm M12 1 5 50 Nm 25 Nm2 6 mm M14 1 5 80 Nm 35 Nm1 6 mm M16 1 5 100 Nm 50 Nm1 8 mm M18 1 5 140 Nm 60 Nm1 8 mm M22 1 5 210 Nm 80 Nm1 10 mm M26 1 5 230 Nm 120 Nm1 12 mm M27 2 330 Nm 135 Nm1 12 mm M33 2 540 Nm 22...

Page 56: ...rly tightened fittings e g with a permanent marker 6 Check all pipes and hose lines and every combination of connecting pieces couplings or connecting points with hoses or pipes to ensure they are in safe working condition 7 4 9 Electrically connecting the axial piston unit NOTICE Short circuit due to penetrating hydraulic fluid Fluid can penetrate the product and cause a short circuit Do not inst...

Page 57: ...anty 1 Switch off the power supply to the relevant system component 2 Connect the HS5E pilot control valve electrically 24 V 7 6 1 Cable sets Accessories for HS5E V L Material number Data sheet Plug in connector 12 pin for central connection XH4 without cable assembly kit R900884671 08006 Plug in connector 12 pin for central connection XH4 with cable set 2 x 5 m R900032356 Plug in connector 12 pin...

Page 58: ... you do not need to carry out any additional wiring for the position transducer systems of the pump and the valve The only wiring that is necessary is to link the 12 pin central connection of the integrated electronics to the customer provided control the pressure sensor and the fieldbus connection that may be present Preassembled cable sets of various lengths are available for the connection If d...

Page 59: ...eceived flashing Module status LEDs 3 and 4 refer to the electronics module For a detailed description of the diagnosis LEDs refer to the functional description of the Rexroth HydraulicDrive Table 18 Indicators of status LED Module status LED LED 4 Indicator status Network status LED Indicator status Off no voltage supply Off no voltage supply Green red flashing Self test Green Operation Green fla...

Page 60: ... the wire labeled 1 to 24 V and the one labeled 2 to L0 Ground The yellow green wire must be connected to ground Fig 21 Connecting the voltage supply of the HS5E pilot control valve Recommendation On the system side the voltage supply of the HS5E pilot control valve should be fuse protected using a 4 A slow blow fuse The HS5E pilot control valve does not have an enable input to block the function ...

Page 61: ...ucer HM20 2X for version HS5E V L P with 4 20 mA current interface has a two wire connection and makes it possible to transfer signals on a noise immune basis across relatively long distances depending on the cable and the permissible ohmic resistance of the pressure transducer Looping in of further pick ups is possible taking into account the respective input resistances For more detailed informa...

Page 62: ... which are located downstream of the flexible pressure hose are favorable for attaching the pressure transducer Always between the pump and a check valve that may be installed Do not use Minimess lines We recommend suspended installation of the pressure transducer to rule out air bleeding problems and any associated control oscillations right from the start If the installation position of the pump...

Page 63: ...n unit Make sure no one is in the danger zone of the machine system The emergency stop button for the machine system should be within the operator s reach Always follow the instructions of the machine system manufacturer during commissioning CAUTION Commissioning an incorrectly installed product Risk of injury and property damage Make sure that all the electrical connections and hydraulic ports ar...

Page 64: ...g ports Air pockets in the area of the bearings The device can be destroyed Make sure that the pump housing is completely filled with hydraulic fluid at commissioning and during operation with the drive shaft upwards installation position Check the hydraulic fluid level in the housing area regularly if necessary recommission With above reservoir installation the housing area may drain via the drai...

Page 65: ...draulic fluids which have been positively evaluated in the Fluid Rating please refer to data sheet 90245 Bosch Rexroth fluid rating list for Rexroth hydraulic components pumps and motors Selection of hydraulic fluid shall make sure that the operating viscosity in the operating temperature range is within the optimum range νopt see selection diagram in the data sheet 92050 To ensure the functional ...

Page 66: ...otors until the hydraulic system is completely filled and air bled To verify drain the hydraulic fluid at the drain port until there are no bubbles in the fluid 8 1 2 Testing the hydraulic fluid supply The axial piston unit should always have a sufficient supply of hydraulic fluid For this reason the supply of hydraulic fluid must be ensured at the start of the commissioning process When you test ...

Page 67: ...ommissioning make sure the axial piston unit was installed in the machine system as intended After starting the drive motor check in particular the specified pressures e g working pressure and case pressure Perform a leak test without and with load prior to normal operation If necessary remove the pressure gauge and plug the ports with the specified threaded plugs 8 1 4 Connection to the control I...

Page 68: ... Ethernet port on your PC or laptop for parallel operation of the Internet for example 8 1 5 Making the basic setting on the control electronics You must have installed the IndraWorks engineering tool to be able to set the control electronics Users must configure the HS5E V L control system to match customer specific requirements This mainly affects the following settings As delivered the command ...

Page 69: ... factory the variable speed mode is deactivated If the control system shall work in variable speed mode this operating mode must be activated and parameterized see data sheet 30237 Z and firmware and software description 30338 FK To set the enable during commissioning you use Easy Startup mode You use IndraWorks to configure this mode and to start it ...

Page 70: ...log inputs with destination actual pressure value 1 P 0 2940 and actual pressure value 2 P 0 2941 The assignment with destination actual pressure value 1 must always be present since an A4Vx O with HS5E V L control system always needs one valid actual pressure value for control Refer to chapter 7 6 8 on page 61 for the various options for connecting a pressure transducer For applications in the cl...

Page 71: ...etting of torque limitation For torque limitation to be able to operate it needs a valid actual pressure value from a pressure sensor 100 corresponds to the torque of the pump at the actually set maximum displacement and to the value of pressure standardization or To protect the drive motor from overloading it is possible to limit the maximum torque of the pump Parameter P 0 2952 Torque limitation...

Page 72: ...he characteristics Flow qv Vg n ηv l min 1000 Torque M Vg Δp Nm 20 π ηmh Power P 2 π M n qv Δp kW 60000 600 ηt Key Vg Displacement per revolution cm3 Δp Differential pressure bar n Rotational speed rpm ηv Volumetric efficiency ηhm Hydraulic mechanical efficiency ηt Total efficiency ηt ηv ηhm Fig 25 Parameters for torque limitation ...

Page 73: ... pressure standardization was input as 350 bar Electric motor M 60 000 P 9549 75 483 9 Nm 2π n 1480 Maximum pump torque M vG Δp 320 350 1782 5 Nm 20π 62 83 Torque limiting Pump relative 483 9 27 1 1782 5 8 1 5 4 Settings of swivel angle sensor At the factory the HS5E V L control system is fitted with the appropriate swivel angle sensor for the pump If the type of swivel angle sensor changes or the...

Page 74: ...alue acquisition 8 1 5 5 Entry of pump and motor values Via the structure tree System pump controller Pump drive motor you can open the following window In this window you must check the values for the displacement of the pump the direction of rotation the hydraulic version the system control and the drive speed and if required adjust them ...

Page 75: ...ts motor is still switched off 1 No fault messages are present and the drive enable is set 2 The actual swivel angle value SWact of the pump is A4 open circuit HS5E close to neutral position via spring centering A4 open circuit HS5EV Vg max or α 100 A4 closed circuit HS5E close to neutral position via spring centering A4 closed circuit HS5EL close to neutral position via spring centering Notice In...

Page 76: ...ult message disappears when the motor is switched on control difference now equal to zero Switching on the drive motor of the pump 8 1 7 Setting controller parameters The following description is to simplify setting of the controller parameters Depending on the application you may not need to modify all of the parameters listed here 8 1 7 1 Setting controller parameters for cascade structure Facto...

Page 77: ...ed of the pump system In the pressure controller there is a path for the integrator with feedback of the change in pressure This makes it possible to limit the integration value at transitions If the actual pressure value is in the range of the accuracy window by the pressure command value the integrator value is not adjusted any more 8 1 7 5 D component Table 23 D component Parameters Designation...

Page 78: ... basis This means that it is generally enough to adapt the controller parameters in the pressure controller Below we will give you information about setting the individual parameters Fig 28 Damped oscillation Step Behavior result Measure 1 Overshoots damped oscillation Check the value of the dead volume P 0 2813 and correct it if necessary 2 Overshoots damped oscillation Increase feedback of integ...

Page 79: ... is still slow Reduce the integration time P 0 2806 0 4 Fig 30 Unstable control Step Behavior result Measure 1 Rapid but unstable response Check the value of the dead volume P 0 2813 and correct it if necessary 2 Reduce P gain P 0 2809 if necessary reduce D component 3 Increase the integration time P 0 2806 0 4 4 Reduce parameter for feedback derivation actual pressure value P 0 2812 Pressure Time...

Page 80: ...ion with a pressure sensor Provision by customer or order of an HS5E V L P control system We recommend calibrating the HS5E V L control system in the following order 1 Calibration of pressure transducer 1 and 2 or A and B if required 2 Calibration of the valve offset 3 Calibration of the swivel angle sensor s offset 4 Calibration of the swivel angle sensor s gain 5 Calibration of leakage compensat...

Page 81: ...ller calibration dialog Fig 32 Calibration For calibrating the HS5E V L control system the hydraulic fluid must have reached operating temperature Attention the calibration function of the swivel angle zero point does not ensure that the pressure in A and B is reached in the closed circuit at 0 swivel angle specification If this is desired the swivel angle zero point has to be readjusted manually ...

Page 82: ...ssively reduce viscosity and damage the product Monitor the operating temperature during the running in phase e g by measuring the leakage temperature Reduce the loading pressure rotational speed of the axial piston unit if unacceptable operating temperatures and or viscosities occur Excessively high operating temperatures indicate faults that have to be analyzed and eliminated The bearings and sl...

Page 83: ...t is not carried out after the running in phase it is recommended to change the hydraulic fluid 8 3 Recommissioning after standstill Depending on the installation conditions and ambient conditions changes may occur in the system which make recommissioning necessary The following criteria may make recommissioning necessary Air in the hydraulic system Water in the hydraulic system Old hydraulic flui...

Page 84: ...which requires no settings or changes during operation For this reason this chapter of the manual does not contain any information on adjustment options Use the product only within the performance range specified in the technical data The machine system manufacturer is responsible for proper project planning of the hydraulic system and its control ...

Page 85: ...d electrical system of the axial piston unit Do not point the high pressure cleaner at sensitive components e g shaft seal ring electrical connections and electrical components For cleaning and care of the axial piston unit observe the following Check whether all seals and plug in connections are securely seated to ensure no moisture can penetrate into the axial piston unit during cleaning Use onl...

Page 86: ...chine system and rectify them This is why Bosch Rexroth recommends always keeping the axial piston unit and system clean Daily Check axial piston unit for unusual noise development Daily Check mounting elements for tight seating Check all fastening elements only when the hydraulic system is switched off depressurized and cooled down Monthly 10 3 Maintenance The axial piston unit is low maintenance...

Page 87: ... units otherwise the functional reliability of the axial piston unit cannot be guaranteed and the warranty will be voided The spare parts lists for axial piston units are order specific When ordering spare parts specify the material and serial number of the axial piston unit as well as the material numbers of the spare parts Address all questions regarding spare parts to your proper Bosch Rexroth ...

Page 88: ...ameters When the Load basic parameters command is executed the current data that matches the control system is lost Before doing this back up the parameters as described in chapter 8 1 9 Saving parameters on page 82 To exchange the HS5E pilot control valve loosen the 4 mounting screws of the HS5E pilot control valve Lift off the HS5E pilot control valve and check and clean the sealing surface Chec...

Page 89: ...t Rexroth part number Cable set Cable length cm R901472424 7000 40501 2410060 60 R901472416 7000 40501 2410070 70 R901472425 7000 40501 2410080 80 R901472418 7000 40501 2410090 90 R901464411 7000 40501 2410100 100 R901472426 7000 40501 2410110 110 R901472420 7000 40501 2410120 120 Please contact us to select the appropriate cable Due to the setting behavior of the seal in the distributor or socket...

Page 90: ...tion 11 3 Performing the removal Proceed as follows to remove the axial piston unit 1 Make sure you have the appropriate tools and wear personal protective equipment 2 Allow the axial piston unit to cool down until it can be removed without danger 3 For below reservoir installation before removing the axial piston unit seal the connection to the reservoir and or drain the reservoir 4 Place a drip ...

Page 91: ...te the parts into Castings Steel Aluminum Non ferrous metal Electronic waste Plastic Seals 13 Extension and conversion Do not modify the axial piston unit and or its assembled parts Unauthorized conversions may cause malfunctions of the control and adjustment system or to failure of the axial piston unit This also includes changing the settings the wiring or the software Changes to settings on the...

Page 92: ...f how your product functions in conjunction with the entire system Try to find out whether or not the product was functioning properly in conjunction with the entire system before the fault occurred Try to determine any changes to the entire system in which the product is installed Have there been any changes to the application conditions or operating range of the product Has maintenance work rece...

Page 93: ... diagnosis At pin 3 of the central connector the signal drive ready can be output For this the factory assignment of the digital output to parameter P 0 0115 bit 1 must be activated This signal can be used to find out whether control is active and that no fault message is present Should a fault message occur during operation or the controller enable be withdrawn this bit is set to 0 Here the follo...

Page 94: ...lic fluid Fill the suction line with hydraulic fluid Remove foreign particles from the suction line Drive speed too high Machine system manufacturer Reduce drive speed Wrong direction of rotation Machine system manufacturer Check correct direction of rotation see chapter 7 4 1 Preparation on page 45 Improper mounting of the axial piston unit Check the mounting of the axial piston unit according to...

Page 95: ...ight too high suction pressure too low foreign particles in the suction line impermissible filter in the suction line Machine system manufacturer Check the system e g optimize inlet conditions use suitable hydraulic fluid Fill the suction line with hydraulic fluid Remove foreign particles from the suction line Hydraulic fluid not in optimal viscosity range Machine system manufacturer Check tempera...

Page 96: ...osch Rexroth Service Malfunction of the control device or controller of the axial piston unit Contact Bosch Rexroth Service Control of the control device defective Check control contact machine system manufacturer or Bosch Rexroth Service Wear or mechanical damage to the axial piston unit Replace axial piston unit Contact Bosch Rexroth Service Output unit defective e g hydraulic motor or cylinder ...

Page 97: ...type polarity Message Wire rupture of swivel angle sensor Defective swivel angle sensor cable visual inspection Replace swivel angle sensor Defective swivel angle sensor Replace swivel angle sensor Internal electronics fault Have the HS5E pilot control valve repaired by the Rexroth Service or replace the HS5E pilot control valve Message Valve error pump controller deviation between command and act...

Page 98: ...r filtration circuit leaky sealing Other unusual noise Drive speed too high Machine or system manufacturer Wrong direction of rotation Machine or system manufacturer Inadequate suction conditions e g air in the suction line insufficient diameter of the suction line viscosity of the hydraulic fluid too high suction height too high suction pressure too low foreign particles in the suction line Check...

Page 99: ...sure transducer defective not connected Diagnosis Measure signal from PT and compare with indication on the pressure gauge Replace pressure transducer see page 89 Connect pressure transducer Control system does not work in closed loop pressure control Increase swivel angle command value Check that the hydraulic system is leak free and that the withdrawal is not excessively high HS5E pilot control ...

Page 100: ... inlet temperature at control system Inspect system e g malfunction in the cooler insufficient hydraulic fluid in the reservoir DB in preload valve opens Diagnosis Pipe to the reservoir heats up Pressure must be lower than the cracking pressure of the preload valve Keep overshoots and pressure pulsation to a minimum Malfunction of the pressure control valves e g high pressure relief valve pressure...

Page 101: ...15 Technical data The permissible technical data for your axial piston unit can be found on the data sheet 92076 The data sheet can be found on the Internet and or in the online product catalog at www boschrexroth de HS5E Order related technical data for your axial piston unit can be found in the order confirmation ...

Page 102: ...tion of rotation 46 Disposal 91 Drive shaft 22 E Eye bolt 38 F Fault diagnosis 93 Filling 65 Flushing cycle 57 Functional test 67 H HFC fluids 31 High pressure side 22 HS5E control system 22 HS5E pilot control valve 88 Hydraulic fluid Selection 31 I Identification 37 IndraWorks Description 35 IndraWorks commissioning tool 35 Inspection 86 Installation 42 Completion 48 General instructions 46 On a ...

Page 103: ...sensor VT SWA LIN G15 87 Replacement of components 87 Required documentation 6 Retaining plate 22 Running in phase 82 S Safety instructions 10 General 12 Product specific 13 Signal word 8 Scope of delivery 21 Seal kits for the pump 88 Spare parts 87 Stand by operation 28 Starting up 27 at zero pressure 27 Starting up at zero pressure 27 Storage 38 40 Storage time 40 Switching over to master slave ...

Page 104: ...y RE 92076 01 B 2021 04 22 Your local contact person can be found at www boschrexroth com addresses Bosch Rexroth AG An den Kelterwiesen 14 72160 Horb a N Germany Tel 49 7451 92 0 sales industry horb boschrexroth de www boschrexroth com ...

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