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Installation 39/132

RE 30201-B/07.2014, SYEPS series 1X,

Bosch Rexroth AG

Note: The minimum line cross-sections and the position of the hydraulic ports can
deviate from the illustration.

The minimum line cross-sections are given in the current hydraulic circuit diagram. The
locations of hydraulic connections can be found in the current installation drawing.
Please observe relevant DIN standards when selecting the lines, e. g. DIN 10305-
1 “Steel tubes for precision applications - Technical delivery conditions - Part 1:
Seamless cold drawn tubes“, DIN EN 856 and DIN EN 853 Rubber hoses and hose
assemblies - Rubber-covered spiral wire reinforced hydraulic type - Specification“.

Fig. 11: Block circuit diagram of variant “High“

SYEPS variant “High“

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Summary of Contents for SYEPS 1X Series

Page 1: ...Operating instructions RE 30201 B 07 2014 Replaces 11 2012 English SYEPS series 1X Highly dynamic electrohydraulic punching system for NC punching machines ...

Page 2: ...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 consent An example configuration is shown on the title page The delivered product may therefore differ from the product whi...

Page 3: ...t 17 4 Scope of delivery 18 4 1 High 18 4 2 Advanced 19 4 3 Standard 20 5 About this product 22 5 1 Performance description 22 5 1 1 Product description 22 5 1 2 Digital axis control HNC100 25 5 1 3 Functional description 28 5 2 Identification of the product 29 5 2 1 Type code of the SYEPS punching system 29 6 Transport and storage 30 6 1 Transporting the SYEHL punching axis 30 6 1 1 SYEHL punchin...

Page 4: ...11 Checking the position control 71 8 1 12 Flushing the hydraulic system 71 8 1 13 Removing the flushing valve and mounting the original pilot valve 72 8 1 14 Adjusting the zero point of the high response valve 73 8 1 15 Testing the machine functions 74 9 Operation 81 9 1 Switch on sequence 81 9 1 1 Boot mode 83 9 2 Operating modes 84 9 2 1 Punching operating modes 84 9 2 2 Forming operating modes...

Page 5: ...g demounting 116 11 3 Demounting 116 11 4 Preparing the components for storage or further use 116 11 5 Replacing components 116 11 5 1 Pilot valve STW243 High STW365 Advanced H 4WEH Standard 117 11 5 2 High response valve High STW243 STW282 117 11 5 3 High response valve Advanced STW365 118 11 5 4 High response valve H 4WEH 10 118 11 5 5 LP accumulator 119 11 5 6 HP accumulator 119 11 5 7 Position...

Page 6: ... cutting forming standardized optimal Drive Control solutions 08101 02 Product information System documentation of the plant manufacturer General information on the complete system Order confirmation Contains the pre set technical data of your SYEPS punching system Installation drawing with spare parts items Drawing Hydraulic and electrical circuit diagram Drawing Punching axis for punching machin...

Page 7: ...ructions Diaphragm type accumulator type HAD 50150 Data sheet Diaphragm type accumulator type HAD2 0 350 50161 B Operating instructions Bladder type accumulator type HAB 50170 Data sheet Bladder type accumulator type HAB 4X 50170 B Operating instructions Mating connectors and cable sets for valves and sensors 08006 Data sheet Service case with test device 29685 Data sheet 1 3 Representation of inf...

Page 8: ...ncrease the legibility of the documentation Table 3 Meaning of symbols Symbol Meaning If this information is disregarded the 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 The following terms are used in this documentation Ta...

Page 9: ...l Code NEMA National Electrical Manufacturers Association NRG Negative Ramp Gradient p Pressure symbol P Power PE Protective Earth pact Actual pressure value POP Position over Plate PRG Positive Ramp Gradient pcomm Pressure command value PSP Position Softpunch PTE Position Tool Exchange PUP Position under Plate SYEPS Electrohydraulic Punch System UB Supply voltage US Undervoltage VDE Verband der E...

Page 10: ...ed use is considered as improper and is therefore not permitted For damage resulting from improper use Bosch Rexroth AG will not bear liability The risks arising from improper use lie exclusively with the user If unsuitable products are installed or used in safety relevant applications unintended operational states may occur in the application that can cause personal injury and or damage to proper...

Page 11: ...the PC program WIN PED A description of the use of the program WIN PED as well as First Steps for its used are provided on the Internet at http www boschrexroth com hnc100 We recommend that users attend a product specific training by Bosch Rexroth Bosch Rexroth offers qualifying training courses in specific fields You can find an overview of training contents on the Internet at http www boschrexro...

Page 12: ...e heavy 100 kg If handled improperly they can fall down and cause serious injuries or crushing because the parts can be for example sharp edged heavy oily loose or unhandy Transport the SYEPS punching system using suitable lifting gear at the points provided for this purpose Ensure that the unit is in a stable position when being transported to the place of installation Wear personal protective eq...

Page 13: ...r crushed by the installation When engineering your circuit observe functional safety in accordance with for example EN ISO 13849 High pressure Risk of injury caused by ejecting oil jet due to rupture of the weakest system component Shut the system down when an oil jet is ejecting and replace the damaged components Protect the pressure in the system by means of an overpressure element Direct the t...

Page 14: ...ring operation Valves of the SYEPS punching system can get so hot during operation that you may burn yourself Let the SYEPS punching system cool down before touching it Protect yourself by wearing heat resistant protective clothing e g gloves Health damaging hydraulic fluid Risk of intoxication and injury e g eye injury skin damage intoxication upon inhalation and swallowing Always check the lines...

Page 15: ...y See also Chapter 9 2 9 Failsafe operation on page 15 2 8 1 Safety function On NC machines various defects may occur that must however all result in a safe shutdown of the machine For this purpose the HNC100 and the valves used offer the following safety signals and functions Hardware faults are caused by defective hardware cable break of sensors Software errors are caused by incorrect data trans...

Page 16: ...PS punching system feature a failsafe function that allows the axis to be moved to the upper positive stop in the event of a fault Withdrawing the enable signal on the valve is the fastest way of achieving this The response time of the enable input is only a few milliseconds and this method should therefore be preferred over the disconnection from the supply voltage In conjunction with Standard Pe...

Page 17: ...S punching system on its attached parts Never use the SYEPS punching system as handle or step Do not place lay any objects on it Foreign particles and contaminants in the punching system Risk of damage wear and malfunction due to the ingress of contaminants and foreign bodies Contaminants and metal particles can damage the running faces of the piston rod and cause leakage When installing the punch...

Page 18: ...th the following scope of delivery 4 1 High 20 t R901273726 SYEPS 1X 1200 040 020 1 1 Table 6 Scope of delivery of High variant for 20 t 30 t R901273727 SYEPS 1X 1200 040 030 1 1 Table 7 Scope of delivery of High variant for 30 t Qty Material no Description Term Data sheet 1 R901259290 Punching axis SYEHL 2X 1200 040 020 1 1 RE 30200 1 R901121772 Digital axis control SYHNC100 NIB 1 3X P I 00 000 A...

Page 19: ...Punching axis SYEHL 2X 0900 040 020 2 1 RE 30200 1 R901121772 Digital axis control SYHNC100 NIB 1 3X P I 00 000 A587 RE 30139 1 R901205756 Electrical amplifier VT VRRA1 527 2X V001 RE 30045 1 1834486001 Card holder VT3002 1 2X 32F RE 29928 Qty Material no Description Term Data sheet 1 R901251601 Punching axis SYEHL 2X 0900 040 030 2 1 RE 30200 1 R901121772 Digital axis control SYHNC100 NIB 1 3X P ...

Page 20: ...eet 1 R901259292 Punching axis SYEHL 2X 0600 040 020 3 1 RE 30200 2 R901306229 Amplifier VT MSFA1 150 1X V0 RE 30260 1 R901134614 Digital axis control VT HNC100 1 3X P I 00 000 RE 30139 Qty Material no Description Term Data sheet 1 R901246498 Punching axis SYEHL 2X 0600 040 030 3 1 RE 30200 2 R901306229 Amplifier VT MSFA1 150 1X V0 RE 30260 1 R901134614 Digital axis control VT HNC100 1 3X P I 00 0...

Page 21: ...13 Mating connector one piece each Connector no Material no Connector type X1S R901134892 Phoenix Mini Combicon 3 pin X2D R901134861 Phoenix Mini Combicon 12 pin X2A R900218443 HD SUB 15 pin X8M R900218443 HD SUB 15 pin Inspect the scope of delivery for completeness Inspect the scope of delivery for any transport damage SYHNC100 NIB 3X ...

Page 22: ...YEPS punching system can be found in the data sheet and the order confirmation 5 1 1 Product description The SYEPS punching system is a highly dynamic electrohydraulic axis for punching and forming operating modes of NC punching machines The axis can perform punching nibbling marking forming soft punch and cutting movements The punching axis is controlled by the digital axis control HNC100 The dat...

Page 23: ...average dynamics of 800 to 1000 strokes min In the variant SYEPS Standard Performance a 4WEH10 directional valve is employed with which up to 750 strokes min can be achieved Thanks to parameter sets tailored to Rexroth punching solutions as well as efficient programming and diagnostics tools commissioning and servicing efforts are minimized To achieve maximum punching rates the power unit and pipi...

Page 24: ...is in real time The control loop value of the cylinder position controller generates the current for the pilot valve in the valve amplifier These punching axes are provided with a high and a low pressure circuit In normal operation the system operates with more energy efficient low pressure and only changes over to high pressure when forces 50 kN are required The pressure changeover is performed h...

Page 25: ...cylinder Pressure A side cylinder HD accumulator charging HD accumulator charging Enable Start stroke Shield 0 V 24 V HP accumulator charging Fig 3 Pinout of SYHNC100 NIB 1 3X variant High Position transducer Analog inputs Digital inputs Voltage supply Valve outputs Digital outputs Valve command value Valve command value reference HP command value Position PTE reached Position POP reached Position...

Page 26: ...g functions Table 14 Pinout of analog inputs Pin assignment Function Vin1 Pin 1 Pin 2 A pressure on cylinder piston side Vin2 Pin 3 Pin 4 HP high pressure accumulator pressure Cin1 Pin 5 Pin 6 LP low pressure accumulator monitoring Incremental position transducer X8M1 Incremental position transducers must be referenced after having been switched on Enable IN1 Input for activating punching and shea...

Page 27: ...0 V and is usually 0 V when the punching axis is in position in closed loop control With variant Standard Valve command value Vout1 This output provides the control signal for the high response valve 4WEH10 There are two modes a Open loop controlled operation In this case the signal can be either 10 V in this case the cylinder moves upwards at max velocity or it amounts to 10 V The cylinder then m...

Page 28: ... and safety position for the axis function shears More details can be found in Chapter 2 Safety instructions Solenoid A OUT5 This output serves for controlling the solenoid on the A side on the standard variant Solenoid B OUT6 This output serves for controlling the solenoid on the A side of the standard variant OUT7 High variant HP accumulator charging This output is used for activating the accumu...

Page 29: ...ber and the fabrication number at hand You should take a photograph of the nameplate and send it to Bosch Rexroth 5 2 1 Type code of the SYEPS punching system Component series 10 to 19 1X Punching rate 1600 strokes min High 1600 1600 1200 strokes min High 1200 1200 0900 strokes min Advanced 900 0900 0750 strokes min Standard 750 0750 0600 strokes min Standard 600 0600 Stroke length 40 mm 040 Punch...

Page 30: ...system by means of a fork lift truck or suitable lifting gear observing the safety instructions Make sure that the load carrying capacity of your fork lift truck or lifting gear is sufficient 6 1 1 SYEHL punching axis Table 15 Dimensions and weights SYEHL type Dimensions WxHxD Weight High 352 x 715 x 394 mm 160 kg Advanced 250 x 657 x 386 mm 117 kg Standard 325 x 613 x 352 mm 100 kg Dimensions and...

Page 31: ... Storing the SYEHL punching axis The SYEHL punching axis should preferably be stored in the unopened original packaging In the unopened original packaging the maximum storage time of the SYEHL punching axis is 6 months If the SYEHL punching axis is to be stored longer than 6 months provide preservation like for storage after its disconnection and removal see below The storage rooms must be free fr...

Page 32: ...axis see Chapter 10 1 Cleaning and care on page 110 2 Plug all ports air tight 3 Wet non lacquered external metal surfaces of the SYEHL punching axis with a suitable anti corrosion agent 4 Pack the SYEHL punching axis air tight together with a desiccant in an anti corrosion foil 5 Protect the SYEHL punching axis against impacts during storage For further conditions see Requirements in this chapter...

Page 33: ...punching systems can be found in Table 15 Dimensions and weights on page 30 Condensation in the housing Risk of short circuit Let the HNC100 acclimate itself for several hours as otherwise water may condense in the housing The housing of the HNC100 is perforated According to the specified protection class dirt and fluids may easily enter and cause malfunction and short circuit The reliable operati...

Page 34: ...ing make sure that all the seals and plugs of the plug in connections are correctly installed to ensure that they are leakproof and fluids and foreign particles are prevented from entering the product 7 2 2 For the SYEHL punching axis When installing the SYEHL punching axis observe the operating conditions as specified in data sheet 30200 Install the SYEHL punching axis in a punching machine in a ...

Page 35: ...1X Bosch Rexroth AG 7 3 Installation orientation and piping of SYEHL punching axes Fig 8 Vertical installation of the SYEPS punching system piston pointing downwards Anchoring screws Tank line Fig 9 Piping of the SYEPS punching system D line T line Frame ...

Page 36: ... High Item Component Data sheet Component type designation Mat no 1 10 High response valve STW243 29136 MATING CONNECTOR 7PZ31BF6 3PG11KSPEZ 6P PE Pg11 R900021267 1 40 HP accumulator charging valve 4WE6Y73 23183 1 x Z4 plug in connector selection Z4 plug in connector with free wheeling diode with 5 m cable Z4 plug in connector with free wheeling diode with 10 m cable Z4 plug in connector with supp...

Page 37: ...gth 3 m R900776897 USB RS232 Converter R901066684 Cable set VT17220 1X HNC100 3X length 2 m for analog signals connection X2A and digital position measuring systems connection X8M with HP plug in connection and breakout cable R901189300 Plug in connector type 6ES7972 0BA41 0XA0 for PROFIBUS DP R901312863 7 5 Installing the SYEPS punching system Preparations 1 Check the scope of delivery for comple...

Page 38: ...ientation is vertical as shown on the drawing below For dimensional details see installation drawing Fig 10 Mounting bores of the SYEHL punching axis The installation of the T line on the SYEHL punching axis is shown on Fig 10 on page 38 7 5 2 Mounting the SYEHL punching axis hydraulically All ports to be connected are marked with plastic plugs An exception is the tank line port It is plugged with...

Page 39: ...gram The locations of hydraulic connections can be found in the current installation drawing Please observe relevant DIN standards when selecting the lines e g DIN 10305 1 Steel tubes for precision applications Technical delivery conditions Part 1 Seamless cold drawn tubes DIN EN 856 and DIN EN 853 Rubber hoses and hose assemblies Rubber covered spiral wire reinforced hydraulic type Specification ...

Page 40: ...40 132 Installation Bosch Rexroth AG SYEPS series 1X RE 30201 B 07 2014 Fig 12 Punching system of variant High Fig 13 Block circuit diagram of variant Advanced SYEPS variant Advanced ...

Page 41: ...Installation 41 132 RE 30201 B 07 2014 SYEPS series 1X Bosch Rexroth AG Fig 14 Punching system of variant Advanced Fig 15 Block circuit diagram of variant Standard 750 kN Standard ...

Page 42: ...42 132 Installation Bosch Rexroth AG SYEPS series 1X RE 30201 B 07 2014 Fig 16 Punching system variant Standard 750 Fig 17 Block circuit diagram Standard 600 ...

Page 43: ... cables as far away from each other as possible and do not install them in parallel Do not route signal cables through strong magnetic fields Whenever possible install signal cables without any interruptions If intermediate terminals are required use a terminal block with shield bus and ready to connect HNC100 cable max length 2 m Install power cables consisting of two individual wires e g voltage...

Page 44: ...Install power cables consisting of two individual wires voltage supply in parallel or as twisted cable For the total current requirement see the data sheet for the punching axis SYEHL 30200 7 5 4 3 Shielding For signal cables use only cables with a copper braid shield Connect the cable shield on one side on a large area to the metallized plug in connector housing and on the HNC100 side This is ach...

Page 45: ...to the potential of the control cabinet s rear wall that is ground by means of a shield terminal that matches the shield bar An important point is the low impedance connection of the DIN rail with conductive coating to the rear wall of the control cabinet 2 Shield system HNC100 Connect the cable shields to the HNC100 housing using the HD SUB connector The connection to the rear wall of the control...

Page 46: ...46 132 Installation Bosch Rexroth AG SYEPS series 1X RE 30201 B 07 2014 Fig 20 Breakout cable with 15 pin HD SUB connector and open cable end ...

Page 47: ...le type LiYCY 2 x 0 25 mm 2 Outputs Inputs 24 V 0 V Shield Oil temperature Start stroke Enable Recommended Shielded standard cable M12 x 4 Recommended Shielded standard cable M12 x 4 Pressure A side cylinder Pressure A side cylinder HD accumulator charging HD accumulator charging Inc encoder 5 V Inc encoder GND Inc encoder TTL signal B Inc encoder TTL signal A Inc encoder TTL signal A Inc encoder ...

Page 48: ...re A side cylinder Oil temperature Oil temperature Inc encoder 5 V Inc encoder GND Inc encoder TTL signal B Inc encoder TTL signal A Inc encoder TTL signal A Inc encoder TTL signal B Original sensor cable required Yellow White Brown Blue black Red violet Green Cable shield fixed to strain relief of connector housing M12 mating connector HBZMS B Accumulator discharge Enable 10 V max 40 V Error 24 V...

Page 49: ...der 5 V Inc encoder GND Inc encoder TTL signal B Inc encoder TTL signal A Inc encoder TTL signal A Inc encoder TTL signal B Original sensor cable required Yellow White Brown Blue black Red violet Green Cable shield fixed to strain relief of connector housing M12 mating connector HM20 4 20 mA Failsafe Outputs CNC PLC M solenoid M solenoid Solenoid A Enable Ground 0 V Switching input 24 V Switching ...

Page 50: ...HP command value Position PTE reached Position POP reached Position PUP reached Ready HD accumulator charging Recommended cable type LiYCY 5 x 0 25 mm2 24 V DC GND 0 V Enable Command value 10 V Command value ref Actual value 10 V Valve connection Fig 24 Wiring of the high response valve on variant High Install the signal cable from the HNC100 to the amplifier card using a shielded 2 wire cable the...

Page 51: ...ommand value ref 0 V UB 24 V supply Valve connection Control zero Inputs Enable 10 V max 40 V Error 24 VDC max 100 mA Outputs CNC PLC M solenoid M solenoid Control zero GND 0 V Power zero GND 0 V 4700 μF 63 V 100 residual ripple UB Fig 25 Wiring of the high response valve on variant Advanced For Advanced and Standard Mating connector with central screw The screw must be secured by means of Loctite...

Page 52: ...t 24 V Ready 24 V M solenoid M solenoid UB 24 V supply Enable Ground 0 V Switching input 24 V Solenoid B Fig 26 Wiring of the high response valve on variant Standard Table 20 Recommended mating connectors Designation mating connector Symbol DC voltage AC voltage Color Valve side Fitting Material number Z4 12 240 V Gray A M16 x 1 5 R901017010 Without circuitry standard 12 240 V Black B M16 x 1 5 R9...

Page 53: ...ivated directly by the HNC100 because the outputs do not provide sufficient electric power The necessary power can be made available in two different ways The plug in amplifier comprises power electronics in the Z4 plug in connector which energizes and de energizes the solenoid of the on off valve in a wear free manner More detailed information on the plug in amplifier can be found in 30262 Plug i...

Page 54: ...de Limitation of switch off voltage peak to 1 V Table 22 Recommended mating connector with cable Designation mating connector Symbol DC voltage AC voltage Color Material number for cable length 3 m 5 m 10 m Z4L1 PE 1 2 1 2 24 V Black R900032021 R900032015 R900217138 With indicator lamp and Zener diode suppressor circuitry Limitation of switch off voltage peak to 55 V Further information on mating ...

Page 55: ...on the power unit The analog high pressure command value signal HP from the HNC100 must be fed to the VT MSPA1 30 amplifier module of the high pressure pump using a shielded cable and a relay The command value of the low pressure pump LP can be adjusted with the help of the potentiometer as described in Chapter 8 Commissioning on page 57 and cut in and out via the relay LP on The potentiometer and...

Page 56: ...ong original cable without intermediate terminals and connect it directly to the HNC100 If the cable needs to be extended or if it is unavoidable to cut the original cable provide optimum shielding at the place of connection If necessary contact Bosch Rexroth Inc encoder 5 V Inc encoder GND Inc encoder TTL signal B Inc encoder TTL signal A Inc encoder TTL signal A Inc encoder TTL signal B Original...

Page 57: ...correct wiring and malfunction of the electronics 8 1 1 General operating conditions control side system Integration into the control concept of the machine 1 Adhere to the switch on switch off sequence of the SYEPS systems as shown in Chapter 9 1 Switch on sequence on page 81 For error and fault handling see Chapter 14 Troubleshooting from page 122 onwards Ensure correct emergency stop behavior O...

Page 58: ...f the HNC100 30139 B 1 After having installed WIN PED version 6 and saved WinView version 3 5 0 0 on your computer execute the installation by double clicking on file winview_3_5_0_0_setup exe You will be guided through the installation and can also make a language selection German English for the program 2 When executing the program WIN PED you are prompted to select a WinView version Select vers...

Page 59: ...d diagnosis WIN PED version 7 also requires the software WinView 1 Download version 3 5 0 0 to your computer and execute the installation by double clicking on file winview_3_5_0_0_setup exe You will be guided through the installation and can also make a language selection German English for the program 2 Open the program WIN PED 7 First the start page of WIN PED Project will open WIN PED Version ...

Page 60: ...7_01 5 Click on the that precedes the name of the project folder The project Punch_Control_High will be listed 6 Double click on the project and the screen WIN PED Control will open Here select Extras in the menu bar then menu item Options A dialog will appear 7 Double click on Environment and further sub items will appear Here select menu item Select WinView In the window Located WinView versions...

Page 61: ... the individual program parts for further parameterization editing and diagnosis Projects created with WIN PED 6 are not compatible with projects from WIN PED 7 Automatic converting is impossible but the projects can be adjusted manually When entering values in WIN PED you always have to enter a point as decimal separator Example 3 000 V ...

Page 62: ...s 1X RE 30201 B 07 2014 Fig 38 Setting of the Profibus address The baud rate determined by the DP master is automatically recognized by the HNC100 In conjunction with Profibus DP the existing baud rate switch is irrelevant Setting the Profibus address ...

Page 63: ... the status indicator of the Profibus master whether the slave HNC100 runs properly In the case of an error solve the problem with the help of the information provided by the status indicator See to it that the order of data words is correct On the PLC the input words PLC HNC100 must be transmitted first then the output words PLC HNC100 For checking the data transmission from the HNC100 to the PLC...

Page 64: ...R parameter window must be open and sub item Activate polling must be selected in menu item Communication Output words on the PLC check input words of the HNC100 1 Data word 1st data word from the PLC to the HNC100 R454 new mode Here the values as described in Chapter 9 2 Operating modes on page 84 must be transmitted For punching operation value 34 must be transmitted Whether the value has been c...

Page 65: ...ontrolled escaping charging gas Risk of suffocation and risk of injury by components carried along Always use the filling and testing device according to data sheet 50170 and 50150 for draining and charging the accumulators Ensure sufficient ventilation at the place of work In the course of each commissioning the bladder and diaphragm type accumulators must be charged to the prescribed precharge p...

Page 66: ...ith transition piece 2 Connection piece 3 Valve body with pressure gauge 4 Bleeder valve 5 Connection piece for accumulator connection thread 6 Shut off valve of the gas bottle The precharge pressure changes as the gas temperature changes After having filled or drained nitrogen wait until the temperature has equalized before you check the gas pressure To set the precharge pressure proceed as follo...

Page 67: ...nuously observe the pressure gauge while charging the accumulator 9 Close the shut off valve 6 of the gas bottle 10 The precharge pressure is temperature related During charging the accumulator warms up Wait until the accumulator has cooled down 11 Check the precharge pressure and if required correct it 12 Retighten the gas charging screw on the diaphragm type accumulator to 25 Nm via the charging...

Page 68: ...YEPS variant Material number Flushing valve Valve type High R900739342 PILOT VALVE 21 3WRCE 32 20 S M Pilot valve of the high response valve Advanced R901311089 PILOT VALVE STW0365 1X Pilot valve of the high response valve On the standard axis no flushing valve needs to be connected 8 1 6 Connecting the pressure gauge On all variants connect a pressure gauge to connection MND1 for LP measurement T...

Page 69: ...on HP and LP will rise from 30 bar to 60 bar 4 Increase the voltage on the LP potentiometer until the LP pressure gauge indicates 80 bar The low pressure is now correctly set and the potentiometer should be sealed in this position 5 Increase the value of parameter R522 HPmin command value until 85 bar is shown on the HP pressure gauge 3 9 Volt Note this value as HPmin command value so that you can...

Page 70: ...perating mode 52 the axis is first moved to the upper mechanical stop and then referenced Then automatic zero point calibration is carried out Referencing and zero point calibration are completed when output OUT7 of the HNC100 is set to High The operating mode 52 can only be executed successfully if the low pressure is 80 bar 5 bar Otherwise error code 55 is set 8 1 10 Checking the actual position...

Page 71: ...e wiring of the valve The power supply is missing or the polarity of the valve command value signal is reversed 8 1 12 Flushing the hydraulic system To ensure a long service life and low wear the hydraulic system must be flushed until the following oil cleanliness is achieved According to old standard NAS 1638 cleanliness class 5 According to new standard ISO 4406 cleanliness class 16 14 11 Accord...

Page 72: ...nd MP On the Advanced and Standard variants install minimess fittings at MP The tightening torques can be found on the installation drawing 2 Switch the motor on star delta startup HP and LP are 30 bar 3 Close switches LP on and HP on HP will rise to 85 bar LP to 80 bar 4 Set a stroke length of 38 mm by setting R423 POP to 39 000 mm and R425 PUP to 1 00 mm Set R454 new mode to 34 and initiate punc...

Page 73: ...e punching axis must then be at PTE position 38 mm in closed loop control This can be checked with the help of the diagnosis window of WIN PED For adjusting the valve zero point turn potentiometer R316 shown below until A variable A004 following error k in the diagnosis window is 0 010 Fig 42 High response valve STW243 UB UB min UB ON Lvdt zero valve 5 UE UE QA QB LED red LED green Enable Zero poi...

Page 74: ...y of about 1000 strokes min with mechanical stripper the punching cylinder when performing an up stroke is often faster than the springs that pull the punching tool out of the metal sheet This causes the punching cylinder to briefly lose contact with the punching tool When the punching cylinder has reached its position POP above the metal sheet it comes quite abruptly to a standstill and the slowe...

Page 75: ...ommissioning 75 132 RE 30201 B 07 2014 SYEPS series 1X Bosch Rexroth AG Fig 45 Operating mode 34 idle stroke 10 mm with variant High 20 t Fig 46 Operating mode 35 idle stroke 10 mm with variant High 20 t ...

Page 76: ...76 132 Commissioning Bosch Rexroth AG SYEPS series 1X RE 30201 B 07 2014 Fig 47 Operating mode 37 stroke 1 mm with variant High 20 t Fig 48 Operating mode 34 idle stroke 3 mm with variant Advanced 20 t ...

Page 77: ...ssioning 77 132 RE 30201 B 07 2014 SYEPS series 1X Bosch Rexroth AG Fig 49 Operating mode 34 idle stroke 10 mm with variant Advanced 20 t Fig 50 Operating mode 35 idle stroke 10 mm with variant Advanced 20 t ...

Page 78: ... Commissioning Bosch Rexroth AG SYEPS series 1X RE 30201 B 07 2014 Fig 51 Operating mode 37 idle stroke 1 mm with variant Advanced 20 t Fig 52 Operating mode 34 idle stroke 4 mm with variant Standard 750 30 t ...

Page 79: ...ning 79 132 RE 30201 B 07 2014 SYEPS series 1X Bosch Rexroth AG Fig 53 Operating mode 34 idle stroke 10 mm with variant Standard 750 30 t Fig 54 Operating mode 35 idle stroke 8 mm with variant Standard 750 30 t ...

Page 80: ...80 132 Commissioning Bosch Rexroth AG SYEPS series 1X RE 30201 B 07 2014 Fig 55 Operating mode 37 idle stroke 4 mm with variant Standard 750 30 t ...

Page 81: ...CNC PLC CNC PLC CNC PLC CNC PLC CNC PLC CNC PLC Voltage supply Pump motor Pressure controller LP active ER command value Pressure controller HP active ER command value High pressure low pressure reached IN1 Enable OUT4 Ready OUT7 Zero point Accumulator discharge valve Item 1 72 Failsafe valve Item 1 20 Change operating mode Valve enable Mode 52 Y Δ startup Switching on Switching off Standard only ...

Page 82: ...ommand value High pressure low pressure reached Standby Active inactive Standard only CNC PLC CNC PLC CNC PLC HNC Emergency stop signal Pump motor Pressure controller LP active ER command value Pressure controller HP active ER command value High pressure low pressure reached IN1 enable Valve enable Accumulator discharge valve item 1 72 Failsafe valve item 1 20 Active inactive Y Δ startup Emergency...

Page 83: ...e rest position of the selected boot mode 9 1 1 Boot mode After booting of the HNC100 the latter changes over to the boot mode which can be set by means of R parameter 400 boot mode After the enable was withdrawn the boot mode is set and the HNC100 is reset to its basic state The standard operating mode for the boot mode is mode 32 Tool change In this operating mode the state signals that OUT1 is ...

Page 84: ...daptive soft punch Advanced High variants only 43 Zero point correction Standard variant only 52 Referencing run 53 9 2 2 Forming operating modes Table 27 Forming operating modes with associated identifier Forming operating mode No Forming 35 Bottom Stroke Advanced High variants only 36 Forming with stop in PUP 40 Bottom stroke with stop in PUP Advanced High variants only 41 Forming with stop in P...

Page 85: ...ed first during punching and only when the metal sheet has been clamped is the spring of the punching tool compressed The punching tool is mounted so that when the punching tool spring is released the punched edge is always above the lower edge of the stripper When the stripper contacts the metal sheet while the punching stroke is performed a resistance builds up for the stripper that prevents it ...

Page 86: ...0 10 20 30 1 2 3 4 5 6 7 8 9 10 Punching axis in PUP 4 mm 0 40 10 20 30 10 1 2 3 4 5 6 7 9 8 7 0 40 10 20 30 Punching axis in POP 12 mm 10 1 2 3 4 5 6 9 8 Fig 61 1 Position measuring system of punching axis in mm 2 Piston rod 3 Punching tool spring 4 Punching tool 5 Stripper spring 6 Stripper 7 Upper turret 8 Metal sheet 2 mm thick 9 Lower turret 10 Die In this operating mode the cylinder moves to...

Page 87: ... upper positive stop must be at 40 000 mm the lower at 0 200 mm In this operating mode punching strokes can be performed that are synchronized with the metal sheet movement The sequence is as follows The starting point is the rest position above the plate POP Each punching stroke is triggered by a rising edge at digital input IN 2 stroke start The punching axis then moves at velocity NRG set in R4...

Page 88: ...put IN 2 stroke start As long as the digital input stroke start is high the punching cylinder moves between the positions POP and PUP as shown in the figure below POP PUP 0 mm x t IN 2 OUT 2 Position POP reached Start stroke R423 R425 Fig 63 Engraving strokes with associated I O signals Positions and velocities can be set as described in the operating mode punching The operating mode soft punch wo...

Page 89: ...ing By setting output OUT7 the HNC100 signals that zero point correction is completed See Chapter 9 1 Switch on sequence on page 81 operating mode 52 must be executed directly after switching on before another operating mode can be called up This function serves for referencing an incremental encoder in the upper positive stop The reference run is started by a changeover to operating mode 53 The a...

Page 90: ... is not active in position PUP As a consequence the absolute accuracy and repeatability are smaller This operating mode is required for forming by moving to the lower positive stop to prevent an integrator overflow that occurs in the forming operating mode Also when forming metal sheets certain maximum velocities must not be exceeded in dependence upon the metal sheet thickness The downstroke velo...

Page 91: ...e in operating mode bottom stroke This operating mode is used for repositioning like operating mode forming with stop in PUP The operating mode forming with stop PUP using 2 start signals differs from the operating mode forming with stop in PUP in that the punching axis does not automatically return to position POP after the forming time elapsed Returning to position POP is initiated by a second s...

Page 92: ...e velocity at which the axis moves to the failsafe position is set in R parameter 442 failsafe ramp With somewhat greater effort this operating mode can also be used in the event of a voltage failure in order to move the axis smoothly to the upper positive stop To maintain the closed loop controlled movement of the axis the voltage supply of both the high response valve and the HNC100 must be buff...

Page 93: ...ing system can be switched to the stand by mode In this mode no dynamic axis movements can be performed It merely serves to reduce energy consumption while the punching axis is at rest and just has to maintain its position The stand by mode is activated by opening switches LPon and HPon As a result the command value for the ER pressure control valves on the pump is 0 V Another possibility of reduc...

Page 94: ...e online help 9 3 1 Machine data Machine data are provided for configuring zero point calibration of the pressure transducers Fig 69 Basic window in WIN PED 6 To be able to change machine data you have to go online with WIN PED and in the window Punch Control 3x click on the box Machine data or on the associated icon in the icon bar on the left WIN PED 6 ...

Page 95: ...0 Machine data Click the button CPU in the window Change machine data to open a window that shows the pinout of the CPU card Click the button S1 in the window Change machine data to open the window Global AO Slot card 1 S1 Settings for the configuration of slot card 1 CPU S1 ...

Page 96: ...ital encoder 1 Select the desired encoder type in the selection window Global AO Slot card 1 S1 Settings under Encoder digital 2 Click the button next to S1 ENC in the window Global AO Slot card 1 S1 Settings to open the window Global AO Slot card 1 S1 Digital encoder S1 ENC 3 Select the direction and set the resolution in the window Global AO Slot card 1 S1 Digital encoder S1 ENC 1 Open the dialo...

Page 97: ...minate any positive feedback in the control loop 1 Select the dialog window S1 Analog encoder Analog output under Slot card 1 and select type Voltage under Analog output S1 AO 1 2 In the same window you can also set the sign of the output By reversing the sign set here you can eliminate any positive feedback in the control loop 9 3 2 R parameters The R parameters serve to parameterize the software...

Page 98: ...ng system functions Controller R Par Controller Controller parameters Positions Windows R Par Positions Windows Actual position values and accuracy windows of positioning Velocities Times R Par Velocities Times Velocities for command value ramps and time settings The header of the parameter group windows always contains the name of the parameter group and to which axis the parameters are assigned ...

Page 99: ...ate For more details about the individual positions and motion sequences please see Chapter 9 2 Operating modes on page 84 Actual position value of the upper cylinder fixed point in the operating mode referencing For more details please see Chapter 9 2 Operating modes on page 84 Position Soft Punch Position from which on the valve is limited to the value entered in the parameter R449 Valve Stroke ...

Page 100: ... at which dynamic valve stroke limitation is activated The dynamic valve stroke limitation can significantly reduce overshoots while punching with HP LP changeover Controller output value with open loop controlled operation of the axis in the operating modes Flushing 51 and Referencing 53 Max pressure value of the HP pump The pressure value is required to achieve the maximum punching force of the ...

Page 101: ... Rexroth AG 9 3 3 Process variables The process variables can be selected in Diagnosis and Measurement and assist in the optimization of the system and in troubleshooting Fig 74 Process variables window in WIN PED 6 Fig 75 Process variables window in WIN PED 7 ...

Page 102: ...indow S1 Parameters To open this window click on Diagnosis Slot card 1 S1 Parameters In the window that opens the status of outputs is displayed under Digital signals S1 WIN PED 7 or S1 WIN PED 6 Active operating mode The displayed number corresponds to the number described in Chapter 9 2 Operating modes on page 84 The state of digital inputs is shown in window S1 This window can be activated from...

Page 103: ...roller output value of the HNC100 Corresponds to the signal at the analog output of the relevant axis 9 3 4 Measurement Apart from process variables further parameters can be recorded in Measurement Fig 77 Selection of parameters to be recorded in WIN PED 6 Control loop value ...

Page 104: ...D 7 The outputs of the HNC100 are structured by slot cards S1 refers to slot card 1 S2 to slot card 2 etc AO stands for Analog Output S1 AO 1 is analog output 1 of slot card 1 The control loop value of the axis is assigned to output S1 AO 1 the pressure command value of the high pressure pump to output S1 AO 2 Output S1 AO 1 ...

Page 105: ...current values in mA without normalization ENC stands for digital encoder The other abbreviations correspond to those described under analog inputs above S1 stands for slot card 1 and W for the representation as normalized value in units 9 3 5 Data transmission Parameter data transmission over Profibus How to set up the data transmission over Profibus is described in the help on the HNC Bus manage...

Page 106: ...the HNC100 does not accept the value and sets bit 0 to 1 By checking the data word Error bit for 0 you can see whether a transmitted value was taken over or not by the HNC100 In this way both data words together make sure that the values were correctly transmitted to the HNC100 NOTICE Undesirable operational states Non synchronized parameter data transmission to the HNC100 without handshake can re...

Page 107: ...is described in more detail in the online help of WIN PED in the Chapter Bus manager under Acknowledge and error bits It is important to adhere to the order listed above when configuring the communication on the Profibus master Data to be sent from the HNC100 must be defined first input words on the PLC then the data that are to be sent to the HNC100 output words of the PLC To generate this hardwa...

Page 108: ...n Inspect wiring to the position transducer Take electrical measurements on connections If required replace position transducer Connector X8M1 is not plugged in Plug in and secure connector 9 11 Bosch Rexroth Internal HNC error Inform Bosch Rexroth 16 Impermissible operating mode selected Customer PLC error a value was transmitted which does not correspond to a permitted operating mode of the HNC1...

Page 109: ...eck after operating time of 20 min and when oil temperature 30 C Filter clogged Change filter 49 Bosch Rexroth Internal HNC error Inform Bosch Rexroth 50 Cable break of LP pressure sensor 55 LP pressure too high Customer LP improperly set Set pressure correctly see section 8 1 9 on page 70 Low oil temperature Let power unit warm up 1 56 LKP pressure is too low or pressure drop is too fast Customer...

Page 110: ...chine and keep sensitive and important components such as solenoids valves and displays clean Use lint free cloths for cleaning 10 2 Maintenance and inspection schedule WARNING Uncontrolled machine movements Risk of injury while carrying out maintenance work on life systems Unless expressly prescribed otherwise switch the machine off with the master switch lock it and remove key The SYEPS system r...

Page 111: ...at all times 10 2 2 Check for generation of noise Check the complete SYEPS hydraulic system for the generation of noise The generation of noise or an increase in the noise level can indicate a possible failure of one or several components at an early time and helps avoid consequential damage 10 2 3 Check of mounting elements Inspect the mounting elements for proper fit Inspect all of the mounting ...

Page 112: ...lator necessary For recharging nitrogen proceed as described in Chapter 8 1 4 Charging the accumulator on page 65 10 2 6 Oil analysis The service life of the SYEHL punching axis is heavily dependent on the quality of the hydraulic fluid For this reason we recommend changing the hydraulic fluid for the first time after 2 years or 5000 operating hours whichever occurs first or having it analyzed by ...

Page 113: ...ee the operating instructions for hydraulic power units and hydraulic assemblies 07009 10 2 7 Open loop controlled operation of the punching axis with test box VT VET in conjunction with variant High The variant High can be open loop controlled with the help of test box VT VET A detailed description of the test box is included in data sheet 29685 Fig 82 Test device VT VET Before connecting the val...

Page 114: ...fier can be found in Chapter 4 Scope of delivery on page 18 Spare parts are also available for the individual variants of the SYEHL punching axis The item numbers in the individual spare parts tables correspond to the item numbers on your installation drawing Table 34 Spare parts for SYEHL punching axis variant High Item Mat no Type code Data sheet Term 1 10 R901018552 STW 0243 1X 3WRCE32V000L SG2...

Page 115: ... variant Standard Item Mat no Type code Data sheet Term 1 10 R901280399 H 4WEH 10 E34 4X 6EG24N9K4 10B20 SO891 24751 High response valve R901280353 4WE 6 J85 6X EG24N9K4 B20 SO891 Pilot valve of high response valve 1 20 R900935006 3WE 6 B6X EG24N9K4 SO9 23178 Failsafe valve 1 40 R901164373 1 HAD2 0 350 2X 2G05E5 1N111 CE 50150 LP accumulator 1 55 R913001637 POSITION TRANSDUCER BAV P PH 00028 01 Po...

Page 116: ...rge the gas pressure of the accumulator NOTICE Spilled or discharged hydraulic fluid Environmental pollution and contamination of the groundwater When draining the hydraulic fluid always place a catch pan under the SYEPS punching system Observe the information in the safety data sheet for the hydraulic fluid and the specifications provided by the system manufacturer 4 Loosen the lines and collect ...

Page 117: ...ting orientation The port pattern on the control block must be 100 identical with that of the valve Attention Installing the size 10 valve wrongly rotated by 180 degrees will result in oil leakage 7 Mount the new components applying the tightening torque specified on the installation drawing In the case of valves provided for subplate mounting take care that the mounting screws are tightened cross...

Page 118: ...es with WIN PED See to it that the variable MD P004 1 actual velocity value is recorded as well The velocity for extending and retracting must be 290 10 mm s For adjusting the velocity loosen both locknuts 1 Completely turn out both stroke limiting screws 2 then turn in again by 1 5 turns Adjusting the downward movement stroke limitation on A side If the velocity is too high or too low increase or...

Page 119: ...w measuring tape flush with the positive stop and glue it on so that it is placed centrally on the adhesive surface It must be glued on straight in order that it runs in parallel to the outer edges of the adhesive surface The measuring tape must not protrude 5 Press the measuring tape firmly on the surface 1 Clean the mounting screws and apply Loctite 243 2 Mount the new measuring head with its mo...

Page 120: ...ge 73 11 5 7 2 Pressure relief valve DBDS When installing the valve observe the correct tightening torque which can be found in the installation drawing and make sure that the seal is properly installed 11 5 7 3Accumulator discharge valve KSDER When installing the valve observe the correct tightening torque which can be found in the installation drawing and make sure that the seal is properly inst...

Page 121: ...e environment Therefore dispose of the SYEPS punching system the hydraulic fluid and the packaging material in accordance with the currently applicable regulations in your country Dispose of hydraulic fluid residues according to the applicable safety data sheets for these hydraulic fluids 13 Extension and conversion The SYEPS punching system may only be converted or extended in the case described ...

Page 122: ...o get a clear idea of the error cause If possible ask the direct machine operator If you cannot rectify the error contact one of addresses which can be found at www boschrexroth com addresses 14 2 Oil cleanliness The oil cleanliness is decisive for the service life and reliability of a high dynamics punching axis About 80 of all problems arising with hydraulics can be traced back to contamination ...

Page 123: ...be checked in cooperation with Bosch Rexroth Malfunction or destruction of electronic components Incorrect wiring Inspect wiring and check electrical signals with the help of measuring equipment and the diagnosis function of WIN PED If required replace electronic components and correct wiring Punching axis does not move or moves in an uncontrolled manner or vibrates Incorrect installation of elect...

Page 124: ...fective connection cable Incorrect wiring Check and if required correct wiring Loose connection and contact problems Inspect connection cable and contacts and if required correct Data transmission over Profibus to the HNC100 does not work reliably Incorrect timing of data transmission Use of handshakes that ensure that data are transmitted properly before the next stroke is initiated Axis is sligh...

Page 125: ...act the hydraulics planner Compare the results calculated or simulated by the planner with the measured operating profile If required make corrections Step response of the high response valve is too slow Check the type code and step response of the valve Request step response data from Rexroth If required replace valve Improperly dimensioned piping Check piping Too slim or too long pipes and hoses...

Page 126: ...ion in the PLC Due to inconsistent data transmission in the PLC while writing data words to the Profibus incorrect values may be sent If the value to be sent over Profibus to the HNC100 is outside the value range permitted by the HNC100 the value is not accepted and the error bit in the 2nd data word of Profibus communication is set By inserting a B variable in the place of the incorrect R paramet...

Page 127: ...ww boschrexroth com Ordering address Headquarters Bosch Rexroth AG Hydraulics Zum Eisengießer 1 97816 Lohr am Main Germany Tel 49 0 93 52 18 0 info boschrexroth de applications centre boschrexroth de or the sales organization Contacts for repairs Service Hydraulics Bgm Dr Nebel Str 8 97816 Lohr am Main Tel 49 0 9352 40 50 60 service boschrexroth de http www boschrexroth com service ...

Page 128: ...mounting and replacement 116 Digital axis control VT HNC100 analog inputs 26 analog outputs 27 digital inputs 26 digital outputs 27 pinout 25 position transducer inputs 26 wiring 45 Digital inputs 26 Digital outputs 27 Disposal 121 E Electrical connection 43 Engraving marking 37 88 Environmental protection 121 Establishing the connection between HNC and PC 63 Extension and conversion 121 F Failsaf...

Page 129: ...cription 22 Personal protective equpment 15 Pinout 47 Place of installation of HNC100 valve amplifiers and amplifier modules 44 Position tool exchange 32 86 Position transducer inputs 26 Pressure controller wiring 55 Pressure gauge connection 68 Pressure sensors wiring 54 Process variables 101 Product description 22 Profibus protocol 106 Punching 34 87 Punching operating modes 84 Q Qualification 1...

Page 130: ... list 114 Storage 31 Suppressing interference 44 Switch on sequence 81 Symbols 8 T Technical data 126 Terms 8 Test device VT VET 113 Testing the machine functions 74 Testing the Profibus data transmission 63 Transport 30 Troubleshooting 122 Type code 29 U Unpacking 34 V Visual indicators 16 Voltage supply 44 W WIN PED installation 58 Wiring high response valve 50 incremental position transducer 56...

Page 131: ...Alphabetical index 131 132 RE 30201 B 07 2014 SYEPS series 1X Bosch Rexroth AG ...

Page 132: ...Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Tel 49 0 9352 18 0 info boschrexroth de www boschrexroth com Subject to revision Printed in Germany RE 30201 B 07 2014 ...

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