Bosch Rexroth VT-VPCD Series Operating Instructions Manual Download Page 1

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Company Registered in England No: 4167649 VAT Registration No: 732 5692 25 BS EN ISO 9001:2008 No: LRQ 0964389

+44 (0)1204 699 959

[email protected]

Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK

www.hyquip.co.uk

/web/index

Operating instructions

RE 30028-B/09.13

Replaces: 10.12

English

VT-VPCD

Digital closed-loop control electronics for axial piston pumps
A4VS... with HS4 control and A2V... with EO4 control

Summary of Contents for Rexroth VT-VPCD Series

Page 1: ...1204 699959 enquiries hyquip co uk Hyquip Limited New Brunswick Street Horwich Bolton Lancashire BL6 7JB UK www hyquip co uk web index Operating instructions RE 30028 B 09 13 Replaces 10 12 English VT VPCD Digital closed loop control electronics for axial piston pumps A4VS with HS4 control and A2V with EO4 control ...

Page 2: ... 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 This document as well as the data speciﬁcations and other information set forth in it are the exclusive property of Bosch Rexroth It may not be reproduced or given to third parties without its...

Page 3: ...damage to material and the product 12 4 Scope of delivery 13 5 About this product 14 5 1 Performance description 14 5 2 Product description 14 5 2 1 Circuit variants 15 5 2 2 Block circuit diagrams 20 5 2 3 Display and operating elements and test sockets 23 5 2 4 Pinout of the edge connector 25 5 3 Identiﬁcation of the product 28 6 Transport and storage 28 6 1 Storing the VT VPCD 28 7 Installation...

Page 4: ...sing BODAC with WinView 50 10 Maintenance and repair 51 10 1 Cleaning and care 51 10 2 Maintenance 51 10 3 Repair 51 11 Removal and replacement 52 11 1 Preparing the removal 52 11 2 Removal 52 11 3 Preparing components for storage further use 52 12 Disposal 52 12 1 Environmental protection 52 13 Extension and conversion 52 14 Troubleshooting 53 14 1 How to proceed for troubleshooting 53 14 2 Error...

Page 5: ...the digital control electronics VT VPCD 1 2 Required and supplementary documentation Only commission the product when you have the documents identiﬁed with the book symbol at hand and have understood and observed them You can ﬁnd operating instructions and data sheets on our website www boschrexroth com mediadirectory Table 1 Required and supplementary documentation Title Document number Document ...

Page 6: ... the risk of personal injury or damage to equipment The measures described for averting the hazard must be observed Safety notes are structured as follows SIGNAL WORD Type and source of hazard Consequences in the case of non observance Measures to avert the hazard List t Warning symbol draws attention to a hazard t Signal word identiﬁes the degree of hazard t Type and source of hazard identiﬁes th...

Page 7: ...e product cannot be used or operated in an optimum manner Individual independent step of action 1 2 3 Numbered instructions for action The numbers indicate that the activities are to be carried out consecutively 1 3 3 Terms used The following terms are used in this documentation Table 4 Terms Term Meaning LVDT Linear Variable Diﬀerential Transformer position transducer UB Operating voltage BODAC B...

Page 8: ...ton pumps The product is intended exclusively for professional use and not for private usage Operation according to the intended use also implies that you have read and understood this documentation completely especially Chapter 2 Safety instructions 2 3 Improper use Any use other than described in the section Intended use is considered as improper and is therefore not permitted For damage resulti...

Page 9: ... the safety regulations and rules of the country where the product is used operated t Use Rexroth products only in technically perfect condition t Observe all notes given on the product t Persons who install commission operate demount or maintain Rexroth products must not consume any alcohol drugs or pharmaceuticals that may aﬀect their ability to respond t Only use accessory and spare parts appro...

Page 10: ...e shielding The control electronics VT VPCD responds to electromagnetic interference from non shielded improperly installed or wrongly connected cables If the limit values given in the data sheet are exceeded malfunction or uncontrolled movements are possible Adhere to the limit values speciﬁed in the data sheet use only electronics below the EMC limit values or provide proper shielding Electrosta...

Page 11: ...ptocouplers or mains free battery operation High voltage Risk of injury Wire or plug in the control electronics VT VPCD only when it is disconnected from the power supply Lightning Risk of uncontrolled machine movements An inadequate grounding concept or missing equipotential bonding can lead to damage to the electronics Ensure equipotential bonding for the device Failures and defects in the contr...

Page 12: ...ding and damage to supply cables in the case of insuﬃcient dimensioning and or operation with several electrical devices Provide current limitation by overload protection Select an appropriate rating of power supply unit and cables Short circuit Risk of overloading of and damage to the supply cable in the case of a defect of electrical equipment Provide current limitation by means of overload prot...

Page 13: ... delivery 13 60 RE 30028 B 09 13 VT VPCD Bosch Rexroth AG NOTICE Cables lying around Risk of stumbling Install cables and lines so that they cannot be damaged and nobody can stumble over them 4 Scope of delivery The scope of delivery includes the digital control electronics VT VPCD Accessories such as interface cables and card holders are not included in the scope of supply but can be ordered sepa...

Page 14: ... actual values are fed to the control electronics and linked to each other by software The actual power value is formed by the product of actual pressure value and actual swivel angle value The controller software ensures with the help of a minimum value comparator that only the controller is active which is assigned to the relevant working point The control electronics is designed as double sided...

Page 15: ... circuit variants are possible Hydraulic circuit variants t Open circuit t Closed circuit Pump combinations master slave t Circuit with pressure sensorics current t Circuit with pressure sensorics voltage When the axial piston pump A4VSO HS4 is operated in the open circuit a valve connection block is installed between the axial piston pump A4VSO and proportional valve 4WRE6 2X 822 The variant of t...

Page 16: ... master and all the other pumps are hooked up as slaves One pressure transducer can be connected to several control electronics In the case of pressure sensors with current interface the resulting load impedance must be taken into account load impedance per control electronics 100 Ω The voltage drop across an input is 3 5 V at 20 mA and 1 7 V at 4 mA The master board realizes closed loop swivel an...

Page 17: ... UK www hyquip co uk web index About this product 17 60 RE 30028 B 09 13 VT VPCD Bosch Rexroth AG Circuit variant pressure sensorics current Fig 3 Circuit variant pressure sensorics current i p UB b22 b24 b4 b2 d10 UB b22 b24 b4 b2 d10 UB b22 b24 b16 b14 d10 b20 b18 f10 f8 d32 z32 b28 Pump 1 Pump 2 Pump n HM 20 Control electronics 1 Control electronics 2 Control electronics 3 Slave Master Slave An...

Page 18: ...ics voltage Fig 4 Circuit variant pressure sensorics voltage It is also possible to realize a master slave system using a bus system Proﬁbus DeviceNet CANopen In this case parameters are not transmitted via analog inputs and outputs but directly over the bus system This is illustrated in the following Figure Combinations of analog inputs and bus communication are possible as well u p UB b4 b2 d10 ...

Page 19: ...ich Bolton Lancashire BL6 7JB UK www hyquip co uk web index About this product 19 60 RE 30028 B 09 13 VT VPCD Bosch Rexroth AG Circuit variant pressure sensorics voltage and bus communication Fig 5 Circuit variant pressure sensorics voltage with bus communication Pump 1 Pump 2 Pump n HM 20 Control electronics 1 Control electronics 2 Control electronics 3 Slave Master Slave PLC Bus master ...

Page 20: ...swivel angle transducer 2b PROFIBUS interface optional 5 Microcontroller 9 Output driver 13a Pressure sensor current open circuit 2c CAN interface optional 6 Current regulated output stage 10 Proportional valve 13b Pressure sensors current closed circuit 2d Local bus Power command value DI1 Command call up 1 DI2 Command call up 2 DI3 Command call up 4 DI4 Command call up 8 DI5 Slave mode DI9 Enabl...

Page 21: ...onverter 8 Voltage output 12a Pump swivel angle transducer 2b PROFIBUS interface optional 5 Microcontroller 9 Output driver 13a Pressure sensor current open circuit 2c CAN interface optional 6 Current regulated output stage 10 Proportional valve 13b Pressure sensors current closed circuit 2d Local bus Power command value DI1 Command call up 1 DI2 Command call up 2 DI3 Command call up 4 DI4 Command...

Page 22: ...oller 9 Output driver 13a Pressure sensor current open circuit 6 Current regulated output stage 10 Proportional valve 13b Pressure sensor current closed circuit Power command value DI1 Command call up 1 DI2 Command call up 2 DI3 Command call up 4 DI4 Command call up 8 DI5 Slave mode DI9 Enable DI6 DI1 to 5 valid P comm Pressure command value p comm SWA command value α comm master SWA command value...

Page 23: ...te process signals Their conﬁguration is described in the online help The following states are signaled by LEDs t LED green Enable active t LED OK green OK ready t LEDs I1 I4 yellow Binary coded command value call ups t LED I5 yellow Slave mode t LED I6 yellow Command valid t LED I7 yellow Not assigned Using keys ENT ESC UP DOWN you can navigate within the menu and access the individual parameters...

Page 24: ... menu structure The parameter values can be displayed and changed Moreover error messages are shown on the display Software is conﬁgured via the serial interface The graphic below shows the pinout of the D SUB socket on the front panel Fig 10 Pinout of the D SUB socket RS232 The connection for Proﬁbus communication is made using a 9 pin D SUB socket on the front panel optional The graphic below sh...

Page 25: ...ll up 1 5 valid O1 DO1 SWA controller active O2 DO2 Pressure controller active O3 DO3 Power limitation active O4 DO4 Slave mode active O5 DO5 Anglecomm angleact window O6 DO6 pcomm pact window O7 DO7 Rectangular 32 Hz The signals of the control variables can be output at the test sockets X1 Test jack 1 output AO3 X2 Test jack 2 I Test jack GND 5 2 4 Pinout of the edge connector The edge connector ...

Page 26: ...r U reference 10 AI1 Diﬀerential input Actual value MCP 40 4742 pin 2 12 AI1 Diﬀerential input Actual value MCP 40 4742 Pin 5 14 AI4 Diﬀerential input Swivel angle command value U I or U 16 AI4 Diﬀerential input Swivel angle command value U I or U reference 18 AI5 Diﬀerential input Pressure command value U I or U 20 AI5 Diﬀerential input Pressure command value U I or U reference 22 AI6 Diﬀerential...

Page 27: ...nd Table 10 Pinout of edge connector row f Pin Signal Description Function VT VPCD 2 DO7 Discrete output Rectangular 32 Hz 8 AI7 Diﬀerential input Power command value U 10 AI7 Diﬀerential input Power command value U reference For type AWXF004D01 20 L2O LVDT2 pump pin 2 Supply GND 22 L2I LVDT2 pump pin 4 Actual value GND 24 L2I LVDT2 pump pin 3 Actual value signal 26 L2O LVDT2 pump pin 1 Supply sig...

Page 28: ...l number 6 Date of production 7 Serial number 3 3 4 3FYSPUI BEF JO FSNBOZ 8 75 71 9 7 2 3 1 4 5 6 7 6 Transport and storage Transport and store the control electronics VT VPCD in the antistatic packaging in which it is delivered Observe the notes on top of the packaging as well as the notes in Chapter 2 Safety instructions In any case when storing and transporting the electronics adhere to the amb...

Page 29: ...while connected to the power supply Disconnect the relevant system part from the power supply before you plug remove or connect the electronics Damage to the electronics caused by incorrect installation is not covered by the warranty Observe the protection class the voltage supply and ambient conditions as speciﬁed in data sheet RE 30028 Electrostatic discharge Risk of destruction of the control e...

Page 30: ...0023126 Serial interface cable for control electronics R900776897 USB converter for connection to the serial interface R901066684 1 The open card holder may only be used for installation in a control cabinet it does not provide electric shock protection 2 If no voltage supply is provided on the system side 7 5 Installing the VT VPCD Please observe the following notes when installing the VT VPCD co...

Page 31: ... t Before installing the control electronics note down the details on the nameplate If nameplates are no longer visible or legible after the installation you have this data at hand at any time When installing the control electronics VT VPCD proceed as follows 1 Disconnect the relevant rack from the power supply 2 Only remove the card from its package at a protected workplace 3 Open the packaging o...

Page 32: ... with a baud rate of 250 kbit The maximum length of the most distant control electronics must not exceed 280 m Moreover the maximum length of the branch lines of 1 m must be observed The data are transmitted over a shielded twisted pair cable For the setup two bus terminal resistors of 120 Ohm are required Fig 14 Schematic structure of local bus 7 5 2 Connecting solenoids and sensorics Lay solenoi...

Page 33: ...o R901017011 The transducer is connected using a 4 pin mating connector Pg7 G5W1F which can be ordered separately stating material no R900023126 Up to a length of 50 m we recommend the use of 4 x 0 25 mm connection cables of type LiYCYCY When double shielded cable is used the outer shield can be terminated at the entry into the control cabinet the inner shield can be terminated at the control elec...

Page 34: ...pe the swivel angle transducer is installed oil immersed We recommend the use of cable type ÖLFLON PTFE FEP 4 x 0 25 mm by Lapp Kabel When double shielded cable is used the outer shield can be terminated at the entry into the control cabinet the inner shield can be terminated at the control electronics f22 f20 2 1 3 4 5 f24 f26 z10 Fig 18 Connection of swivel angle transducer DK100 Swivel angle tr...

Page 35: ...we recommend the use of 3 x 0 5 mm cables of type LiYCYCY as connection cable When double shielded cables are used the outer shield can be terminated at the entrance in the control cabinet the outer shield can be terminated at the control electronics For the voltage interface pressure transducers of type HM 20 2X H K35 are used Pressure transducer cables must be shielded Cable type for the voltage...

Page 36: ... 09 13 For the current interface pressure transducers of type HM 20 2X C K35 are used Pressure transducer cables must be shielded Cable type for the current interface LiCYC 2 x 0 25 mm2 up to a length of 50 m Fig 21 Connection of pressure transducers with current interface Notes on the technical data and unit dimensions of pressure transducer HM 20 see data sheet RE 30272 VPCD_03 z30 b22 1 4 2 3 z...

Page 37: ...C with ordering code SYS HACD BODAC 01 material number R900777335 can also be downloaded on the Internet www boschrexroth de HACD This software can be used for initial commissioning and convenient operation of the control electronics and for making all the required settings for optimal operation of your VT VPCD control electronics The operating principle integrated menus and program windows of the...

Page 38: ...ﬁle that describes the conﬁguration and handling of your control electronics After having installed the BODAC software proceed as follows 1 Connect the serial interface cable mat no R900776897 to the port of the control electronics VT VPCD 2 Plug the serial interface cable into the serial interface COM port of your PC or if required use a USB converter Mat no R901066684 The control electronics VT ...

Page 39: ... control electronics to a PC For a detailed description of indicator and operating elements see Chapter 5 2 3 Display and operating elements and test sockets on page 23 9 1 1 Menu tree for setup and parameters The display is used for indicating command values and actual values as well as errors For making any settings or parameter changes BODAC has to be used The following overviews are given on t...

Page 40: ...s menu press the Enter key Fig 22 Menu tree Parameters Parameters CMD ramp Binary 0 15 Angle CMD Angle ramp Pressure CMD Pressure ramp Power CMD Pressure control Binary 0 3 100 100 0 300 s 0 1000 bar 0 300 s 0 100 Control P Binary 0 3 Control I Binary 0 3 0 255 0 30000 ms Binary 4 7 Binary 8 11 Binary 12 15 Control P Binary 4 7 Control P Binary 8 11 Control P Binary 12 15 Control I Binary 4 7 Cont...

Page 41: ...ashire BL6 7JB UK www hyquip co uk web index Operation 41 60 RE 30028 B 09 13 VT VPCD Bosch Rexroth AG Setup Language Fieldbus Local Bus English ID ID Level 1 Level 2 Level 3 Level 4 Level 5 Deutsch 0 61 1 32 Fig 23 Menu tree Setup Changes to the bus ID require a re initialization of the control electronics After having successfully saved any changes to the bus ID switch the electronics oﬀ and on ...

Page 42: ... ESC for 5 seconds to get to the menu Analog I O Analog I O Inputs MCP 40 4742 Type Range Min Value V Max Value V Min Fault V Max Fault V 0 10 V 100 11 11 V 11 11 V 11 11 V 11 11 V Level 1 Level 2 Level 3 Level 4 Level 5 Act Pressure A Res Angle CMD Type Range Min Value V Max Value V Min Fault mA Max Value mA Max Fault V Min Fault V Max Fault mA 0 10 V 4 20 mA 0 100 11 11 V 11 11 V 2 22 mA 2 22 mA...

Page 43: ...evel 1 Level 2 Level 3 Level 4 Level 5 Angle CMD Type Range Min Value V Min Value mA Max Value V Min Fault mA Max Value mA Max Fault V Min Fault V Max Fault mA 10 V 4 20 mA 0 100 11 11 V 2 22 mA 11 11 V 2 22 mA 2 22 mA 11 11 V 11 11 V 2 22 mA Pressure CMD Type Range Min Value V Min Value mA Max Value V Min Fault mA Max Value mA Max Fault V Min Fault V Max Fault mA Max Unit 10 V 4 20 mA 0 100 11 11...

Page 44: ...n Bosch Rexroth AG VT VPCD RE 30028 B 09 13 Level 1 Level 2 Level 3 Level 4 Level 5 Act pressure B Type Range Min Value V Min Value mA Max Value V Min Fault mA Max Value mA Max Fault V Min Fault V Max Fault mA Max Unit 10 V 4 20 mA 0 100 11 11 V 2 22 mA 11 11 V 2 22 mA 2 22 mA 11 11 V 11 11 V 2 22 mA 1 0 1000 0 bar Type Range Min Value V Max Value V Min Fault V Max Fault V 10 V 0 100 11 11 V 11 11...

Page 45: ... BL6 7JB UK www hyquip co uk web index Operation 45 60 RE 30028 B 09 13 VT VPCD Bosch Rexroth AG Fig 26 Menu tree Faults Faults Angle CMD Oﬀ Oﬀ Oﬀ Oﬀ Oﬀ Oﬀ Mode Mode Oﬀ Oﬀ 0 01 60 00 sec 0 0 100 0 01 60 00 sec Level 1 Level 2 Level 3 Level 4 Level 5 Stop Stop Stop Stop Stop Stop Debounce Debounce Stop Stop Pressure CMD Power CMD Act Pressure B Act Pressure A Bus Fault Cable break solenoid Swivel a...

Page 46: ...essure B Act Pressure B Act Pressure A Act Pressure A Act Valve Act Valve Res Angle CMD Res Angle CMD Act Angle Act Angle Power CMD Power CMD Valve CMD Valve CMD Act Power Act Power Pressure CMD Pressure CMD Angle CMD Angle CMD Fig 27 Menu tree Test jacks 9 2 Operating the control electronics VT VPCD To make operations directly on the control electronics you can use the four control keys UP DOWN E...

Page 47: ... This saving process takes about one minute During this time do not switch oﬀ the power supply to the control electronics otherwise the changes you made will not be stored in the memory The ESC control key brings you one level up in the menu structure To open the conﬁguration menu press the key combination ENT and ESC The conﬁguration mode is structured by levels The ﬁrst level contains the variou...

Page 48: ...ﬁguration mode In the present example the second level of the menu tree Setup was selected The display of the control electronics shows Sprache Language as running text Press the ESC control key The display shows Setup as running text Press the control key ESC The display shows as running text the manufacturer s name and the version number of the control electronics or a text determined individual...

Page 49: ...ctronics is now at the second level of the conﬁguration menu Analog I O 8 Use the control key UP or DOWN to navigate to the menu item Inputs 9 Press the control key ENT 10 Use the control key UP or DOWN to navigate to the menu item Pressure CMD 11 Press the control key ENT 12 Use the control key UP or DOWN to navigate to the menu item Max Unit 13 Press the control key ENT The value currently set i...

Page 50: ...splay of the control electronics VT VPCD After the control electronics detected an error deﬁned in the BODAC software please proceed as follows The letter combination FAIL will ﬂash on the display of the control electronics Press the ENT key to have the error message shown on the display and eliminate the error The procedure for determining the response in the event of an error is described in the...

Page 51: ... and short circuit Observe strictest cleanliness when carrying out any work on the control electronics VT VPCD Use only dry and dust free cloth for cleaning 10 2 Maintenance In the interest of a long service life and operational reliability include the following activities for the control electronics in your maintenance schedule t Inspect all terminal connections for correct connection and damage ...

Page 52: ...ectronics from the plug in connection without applying any force 11 3 Preparing components for storage further use To prepare the VT VPCD for storage or further use proceed as follows Whenever possible use the original packaging for storage or use another suitable ESD packaging and observe ESD regulations Adhere to the permitted storage temperature range which is speciﬁed in RE 30028 Protect the c...

Page 53: ...he machine operator If you cannot rectify the error contact one of the contact addresses which can be found at www boschrexroth com adressen or in the address directory in the Annex 14 2 Error messages Table 12 Description of error messages Error message Description 10 V reference Reference voltage 10 V b32 or reference voltage 10 V b30 outside the permitted range Power 24 Supply voltage UB z30 le...

Page 54: ...b Short circuit in the connection of solenoid a z2 z4 or solenoid b z6 z8 Bus Fault Proﬁbus The slave has left the state DATA_EXCHANGE CANopen The node has left the state OPERATIONAL DeviceNet The node has left the state ONLINE 14 3 Changing the fuse The control electronics is protected against overvoltage by means of a fuse The fuse is a single use fuse with the following data t F 4 A 250 V The f...

Page 55: ... 7JB UK www hyquip co uk web index Technical data 55 60 RE 30028 B 09 13 VT VPCD Bosch Rexroth AG Fig 30 Fuse of control electronics VT VPCD 3 Test the fuse using a suitable test device continuity test 4 If the fuse is defective replace it with a new one of the same type 5 Reinstall control electronics VT VPCD and perform a functional test 15 Technical data The technical data can be found in data ...

Page 56: ...repairs Bosch Rexroth AG Service Industriehydraulik Bgm Dr Nebel Str 8 97816 Lohr am Main Germany Phone 49 93 52 40 50 60 http www boschrexroth com service e mail repair hydraulics boschrexroth de 16 1 2 Contact for support Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany e mail support hacd boschrexroth com 16 2 Ordering address Headquarters Bosch Rexroth AG Zum Eisengießer 1 97816 L...

Page 57: ...stics 50 Display 24 Display and operating elements and test sockets 23 Disposal 52 E Edge connector pinout 25 Environmental protection 52 Error messages 53 Extension 52 F Fuse change 54 G General instructions 9 General notes on damage to material and the product 12 I Identiﬁcation of the product 28 Improper use 8 Installation 30 local bus 32 Installation conditions 30 Intended use 8 K Keys 23 L LE...

Page 58: ...hire BL6 7JB UK www hyquip co uk web index 58 60 Alphabetical index Bosch Rexroth AG VT VPCD RE 30028 B 09 13 Scope of delivery 13 Serial interface 24 Sign of display value 24 Software BODAC installation 37 system requirements 37 Storage 28 Swivel angle transducer connection 33 Symbols 7 T Technical data 55 Terms used 7 Test sockets 25 Tools 29 Transport 28 Troubleshooting 53 U Unpacking 29 W WinV...

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