REXROTH Sytronix FcP 5020 Operating Instructions Manual Download Page 181

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Maintenance

9.1

System Overview

(1)

Drive controller

(2)

Motor

(3)

Pump

(4)

Hydraulic system

(5)

Pressure transducer (pact = actual pressure value)

Fig. 9-1:

System overview

9.2

Drive Controllers

Regularly check the filters at the air inlets of the control cabinet. Replace or

clean dirty filters. The electrical components themselves do not require main‐

tenance.

9.3

Motor-pump Unit

See documentation of the component:

Title

Material number

Documentation type

Rexroth Sytronix FcP50xx/70xx Motor-Pump Unit MPES2

R911342715

Operating instructions

Rexroth Sytronix Motor-Pump Unit MPES2 PGF/PGH-MOT-FC

R911345047

Mounting instructions

Rexroth Sytronix Motor-Pump Unit MPES2 A4VSO / A10VZO on MOT-FC

R911345048

Mounting instructions

This documentation contains references to supplementary doc‐

umentation for the individual components (motors, pumps, hy‐

draulic fluid, etc.).

Tab. 9-1:

Documentation, motor-pump unit

DOK-SYTROX-FCP5020****-IT01-EN-P

Bosch Rexroth AG

179/201

Frequency-controlled pump drive system Sytronix FcP 5020

Maintenance

Summary of Contents for Sytronix FcP 5020

Page 1: ...Frequency controlled pump drive system Sytronix FcP 5020 Operating Instructions R912008034 Edition 01...

Page 2: ...as in the event of applications for industrial prop erty rights Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristi...

Page 3: ...d to Specific Dangers 23 3 3 1 Protection against Contact with Electrical Parts and Housings 23 3 3 2 Protective Extra low Voltage as Protection against Electric Shock 24 3 3 3 Protection against Dang...

Page 4: ...t 49 6 4 2 Hydraulically Connecting the Motor Pump Unit 49 6 4 3 Connection Technique 50 General Notes 50 Power Connection 52 Connect the Motor Fan 56 6 4 4 Connection EFC 5610 for FcP 5020 57 Digital...

Page 5: ...ion 98 7 4 2 Master Slave Function 99 7 4 3 Sleep Wake Function 101 7 4 4 Two Points Double Pump Control 103 7 4 5 Pressure Drop Overshoot Compensation 105 7 4 6 Pump Power Limitation 106 7 4 7 Hydrau...

Page 6: ...meter List 144 7 11 2 Group b System Parameters 144 b0 Basic system parameters 144 7 11 3 Group C Power Parameters 145 C0 Power control parameters 145 C1 Motor and system parameters 147 C2 V f control...

Page 7: ...haracters 187 14 2 Status Code 187 14 3 EFC Warning Code 187 14 4 EFC Error Code 188 14 4 1 Error 1 OC 1 Overcurrent at Constant Speed 188 14 4 2 Error 2 OC 2 Overcurrent during Acceleration 188 14 4...

Page 8: ...4 30 Error 45 E Par Parameter Settings Invalid 194 14 4 31 Error 46 U Par Unknown Parameter Restore Error 194 14 4 32 Error 48 idA Internal Communication Error 194 14 4 33 Error 49 idP Internal Parame...

Page 9: ...mbly commissioning maintenance disassembly and simple troubleshooting of the product You should read this documentation completely and in particular chapter 2 Safety Instructions on page 13 before wor...

Page 10: ...911343624 Project planning manual Motor Rexroth Sytronix Safety Notes and Instructions on Use Motor Pump Unit R911343643 Safety notes Motor Pump Unit Internal gear pump PGF Series 2X and 3X 10213 Data...

Page 11: ...ase refer to R912005854 this document can be downloaded or purchased from Bosch Rexroth 2 Since the sytronix controller have been embedded to EFC converter both documents Sytronix FcP 5020 and EFC 561...

Page 12: ...avoidance measures Enumeration Warning sign Draws attention to the danger Signal word Identifies the degree of danger Type and source of danger Identifies the type and source of danger Consequences D...

Page 13: ...d in this documentation Abbreviation Meaning FcP system Frequency controlled pump system p Pressure Q Flow rate n Speed PGF PGH PGM Internal gear pump constant displacement volume RE Rexroth document...

Page 14: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 12 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 15: ...is designed The FcP system may be used as follows For pressure controlled hydraulic supply with override flow control The FcP system is not suitable for performing safety relevant functions A plausibi...

Page 16: ...the safety regulations and provisions of the country where the product is implemented used Exclusively use Rexroth products in technically perfect condition Observe all notices on the product Persons...

Page 17: ...depres surized Keep open fire and ignition sources away from the FcP system WARNING High electrical voltage above 50 V Danger to life risk of injury caused by electric shock or severe injury Make sur...

Page 18: ...om missioned and operated Areas in which motor parts with permanent solenoids are stored repaired or mounted Consult a doctor if the persons specified above have to work in these areas CAUTION Hot FcP...

Page 19: ...fety goggles protective gloves suitable working clothes safety shoes If nevertheless hydraulic fluid comes into contact with the eyes or gets into the bloodstream or is swallowed please consult a doct...

Page 20: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 18 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 21: ...ca bles Installation An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a s...

Page 22: ...mark them to be trained or instructed to maintain and use adequate safety equip ment to attend a course of instruction in first aid User A user is a person installing commissioning or using a product...

Page 23: ...tion documentation in the available language please ask your supplier to clarify Proper and correct transport storage mounting and installation as well as care in operation and maintenance are prerequ...

Page 24: ...accordance with European EN standards United States of America USA National Electrical Code NEC National Electrical Manufacturers Association NEMA as well as local engineering regulations Regulations...

Page 25: ...t electric components from the mains or from the power supply unit Secure the electric component from reconnec tion With electric components observe the following aspects Always wait 30 minutes after...

Page 26: ...AWG 25 mm2 4 AWG 70 mm2 2 0 AWG 35 mm2 2 AWG Tab 3 1 Minimum cross section of the equipment grounding connection 3 3 2 Protective Extra low Voltage as Protection against Electric Shock Protective ext...

Page 27: ...ntrol system are installed As a result of the risk assessment the user must provide for monitoring func tions and higher level measures on the installation side for personal safety The safety regulati...

Page 28: ...tro magnetic compatibility EMC test 3 3 4 Protection against Electromagnetic and Magnetic Fields during Oper ation and Mounting Electromagnetic and magnetic fields Hazards for persons with active medi...

Page 29: ...pective safety regulations the manufacturer of the machine or installation must take measures to avoid injuries caused by burns in the final application These measures can be for example Warnings at t...

Page 30: ...ct Planning Manuals motors and components cooled with liquids and compressed air can be partially sup plied with externally fed pressurized media such as compressed air hy draulics oil cooling liquids...

Page 31: ...or malfunctions in the FcP system Ensure that all connections hydraulic lines and attachment parts e g measuring devices are clean and free of chips For removing lubricants or any other heavy contami...

Page 32: ...destroyed Observe the system manufacturer s specifications regarding the point Control of the hydraulic fluid and the prescribed remedial measures for the control result NOTICE Leaking or spilt hydra...

Page 33: ...cedes the signal words DANGER WARNING and CAUTION is used to alert the reader to personal injury hazards DANGER In case of non compliance with this safety instruction death or serious injury will occ...

Page 34: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 32 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 35: ...he feedback to the frequency converter The frequency converter controls the speed of the asynchronous motor so that the pump driven by it displaces exactly the oil volume required for providing the co...

Page 36: ...SO EZ axial piston pump shown here PGF Fig 4 2 Sytronix FcP 5020 Pressure transducer Fig 4 3 HM20 2X pressure transducer For more information regarding the pressure transducer please refer to the Pres...

Page 37: ...lation of EFC for FcP in a Cabinet Fig 4 4 Set up of EFC 5610 for FcP in a cabinet DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 35 201 Frequency controlled pump drive system Sytronix FcP 5020 About t...

Page 38: ...designation 2 Motor power 3 Input voltage type input voltage range input current input frequency 4 Output voltage type output voltage range output current output frequency range 5 Ambient temperature...

Page 39: ...rial number 3 QR code Internal use 4 Serial number of product 5 Version 6 Production data Fig 4 8 QR code of EFC 5610 for FcP 5020 DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 37 201 Frequency contro...

Page 40: ...rmware The ASF type code will not be printed and placed on the EFC converter but only a square adhesive label on the side which represents important infor mation from ASF type code For example Fig 4 1...

Page 41: ...F API incompatible Bit11 Reserved Bit12 ASF runtime exceeded Bit13 ASF stack overflow Bit14 Bit15 Reserved Tab 4 1 FcP 5020 ASF basic information For accurate information refer to the actual data prov...

Page 42: ...will be ignored and taken over by the ASF terminal assignment non zero entries in ASF For details about the wiring of temperature sensor as shown in the diagram above please refer to EFC 5610 Operati...

Page 43: ...al Signal function Description Signal requirement 10 V Power supply for analog inputs GND is reference Max output current 30 mA 5 V Max output current 10 mA AI1 Analog voltage input 1 Analog current i...

Page 44: ...ure sensor power supply please set E2 26 to active Voltage output 0 10 V Maximum load current for voltage output 5 mA Current output 0 20 mA Maximum load resistance for current output 332 EAO Analog o...

Page 45: ...must be read through and followed before any operation on these two terminals Fig 4 13 Grounding and PE terminals 1 Grounding terminal for mains cables 2 Reserved for PE shielding adapter Order addit...

Page 46: ...before plugging or unplugging the connector The terminal block is ONLY for wiring convenience which CAN NOT be used for fixing the cables Additional measures need to be taken by users for cable fixin...

Page 47: ...ing documentation for each component Title Material number Documentation type Rexroth Frequency Converter EFC 3610 EFC 5610 Series edition 07 R912005854 Operating Instructions Tab 5 1 Documentation dr...

Page 48: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 46 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 49: ...components mounting surfaces and threads to ensure they are clean Make sure that the assembly can be carried out in a dry and dust free environment Ensure that the motor pump unit and all other used...

Page 50: ...uid according to ISO4406 is complied 6 3 2 Installation Conditions for Frequency Converter and Additional Com ponents The frequency converter and its additional components have been designed for insta...

Page 51: ...d pressure port Immediately wipe off any leaking oil Check the line for cleanliness Ensure that the line connection contains the specified sealings Lock O rings with assembly grease against slipping i...

Page 52: ...quency consist with the nominal data A connection overview for power and accessory connections PTC can be found within the terminal box The con nections must be established such that a permanent safe...

Page 53: ...Terminal boxes with cable ducts for motor fan connection only available for forced ventilated motors Fig 6 2 Connection Overview DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 51 201 Frequency controll...

Page 54: ...to this mark 4 The exposed cable shield must be split acc to chapter chapter Con nection Total Shield Power Cables on page 53 All further working steps about shield assembly can be done immediately or...

Page 55: ...ble within the terminal box to keep a HF suitable connection Therefore connect the shield via a ring terminal and a screw with the termi nal box A connection screw is provided within the terminal box...

Page 56: ...o the wires after connecting within the terminal box 2 Split the total shield of the cable braid open Fig 6 6 Split the shield braid open Split the shield braid open very carefully via the complete st...

Page 57: ...or for motor protection must be connected to the drive controller Observe the connection designation under fig 6 4 Connection designation within terminal boxes on page 53 and the notes about temperatu...

Page 58: ...fan terminal box and shows the connection for 230 V and 400 V The interconnection is factory adjusted designed for 400 V Fig 6 9 Connection scheme motor fan The following table contains electrical po...

Page 59: ...C 5610 for FcP 5020 Digital input NPN PNP wiring NPN wiring with internal power supply NPN wiring with external power supply PNP wiring with internal power supply PNP wiring with external power supply...

Page 60: ...V or 5 V For external supply its reference ground MUST be connected to termi nal COM Relay output terminals When relay output terminals are connected with inductive loads relays con tactors solenoid...

Page 61: ...ally open contact RC RC filtering VDR Varistor D Diode Fig 6 12 Noise suppression circuits for relay output terminals DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 59 201 Frequency controlled pump dri...

Page 62: ...heck valve in the line be tween the pump and the pressure transducer apart from the pre load valve If there is no pre load valve in the system you can assemble the pres sure transducer directly at the...

Page 63: ...3610 EFC 5610 Series see chapter 1 About this Documenta tion on page 7 For the assembly and installation of the electric components of the FcP sys tem in the control cabinet you need the following doc...

Page 64: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 62 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 65: ...ires following components Motor coupling and pump 1 pressure sensor at the pump output side and behind check valve if it is available In order to keep the positive direction of pump which gener ates p...

Page 66: ...essure sensor Quick configuration for Rexroth MOT FC_HOY motor p Q PID control p Q control with automatic switching between pressure and flow control modes Flow control Pressure control With 2 groups...

Page 67: ...for cleanliness Fill in the hydraulic fluid according to the machine manufacturer s regu lations Only use filters with the required minimum retention rate Activate the safety equipment and monitoring...

Page 68: ...nd fixed See chapter 4 4 4 Control Terminals on page 44 Power terminals Power terminals can be found on the bottom of the converter behind the control terminals 7 2 4 Operating Preparation The LED pan...

Page 69: ...TI switch threshold 0 E2 25 AO1 output mode F3 16 Differential gain 0 E2 26 AO1 output setting F3 17 Filter time for Kd 0 F1 00 ASF parameter initialization F3 18 Lower limit for I D 0 F1 01 Control...

Page 70: ...FcP 5020 dialog Sytronix system can also be configured via commissioning dialog under engi neering software IndraWorks this dialog Sytronix appears automatically in IndraWorks navigator if the followi...

Page 71: ...are shown with white background dropdown menu or klick point these values can be directly edited via GUI which works exactly like parameter changing via parameter editor By right click on the paramet...

Page 72: ...FcP 5020 dialog After click the Basic commissioning button an additional window will be open as shown in the figure shown as below in this check list customer will find the most corresponding functio...

Page 73: ...00 0 Stop F2 07 Analog input for pressure feedback 0 bar 0 0 5 0 V mA 4 0 Stop F2 08 Flow command corresponding to 10 V 20 mA 1 3 000 rpm 400 Stop F2 09 Analog input for flow command 0 rpm 0 0 5 0 V m...

Page 74: ...operation mode can be changed In 2 Communication Interface there are two main blocks Communication Input and Communication Output which includes all IO and bus communi cation settings In the followin...

Page 75: ...ion there is a link for configuration the master communication there the communication protocol could be selected however the most configura tion for bus communication should be done on the PLC master...

Page 76: ...pressure feedback Code Name Setting range Default Min Attri E1 35 AI1 input mode 0 0 20 mA 1 4 20 mA 2 0 10 V 3 0 5 V 4 2 10 V 2 Run E1 40 AI2 input mode 1 Run H8 05 EAI input mode 0 4 same as E1 35 5...

Page 77: ...H 19 Other 0 10 V pressure sensor 3 Stop Tab 7 4 Parameter list of HM20 pressure sensor auto selection The pressure conductor for hydraulic pressure control can be configured un der 4 Pressure Feedba...

Page 78: ...ssure feedback corresponding to 10 V 20 mA 0 1 1 000 0 bar 100 0 Stop F2 07 Analog input for pressure feedback 0 bar 0 0 5 0 V mA 4 0 Stop F2 08 Flow command corresponding to 10 V 20 mA 1 3 000 rpm 40...

Page 79: ...Pressure command scaled by F2 04 2 Pressure feedback scaled by F2 06 3 Setting speed include direction scaled by F2 08 4 Output speed include direction scaled by F2 08 0 Run Tab 7 6 Analog output AO1...

Page 80: ...p F2 19 X4 input 0 Stop F2 20 X5 input 0 Stop Tab 7 7 DI parameter list The default setting of terminal X1 X5 in ASF is 0 this means no function is assigned from ASF the function of DI setting in EFC...

Page 81: ...FcP5020 dialog Communication In put IO Setting IO setting must be selected Digital and Relay Output Code Name Setting Range Default Attri F2 36 DO1 output 0 No function assigned from ASF 1 Converter w...

Page 82: ...55 kW 20 75 kW 21 90 kW 0 Stop Tab 7 11 Motor parameter list Only change motor parameter by switching F1 16 to 1 21 when F1 15 1 If F1 15 0 no motor parameter will be changed by switch ing F1 16 and...

Page 83: ...Motor configuration By project using third party motor these motor data can be configured by clicking the link Motor parameter which will open a new window for Auto Tuning For asynchronous motor the...

Page 84: ...Fig 7 16 Motor parameter Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 82 201 Frequency controlled pump drive system Sytronix FcP 5020 Commissioning of Sytronix FcP 5020 System...

Page 85: ...sensor should be correctly connected to EFC 5610 according to the wiring diagram then set E1 60 to the sensor channel and E2 26 to 11 to active the motor thermal protection over PTC sensor Flow and p...

Page 86: ...sure command have been set to 400 rpm and 10 bar to ensure a safe startup reduce this values if necessary F1 03 F1 12 Error in the motor pump unit control Damage to property Make sure that all connect...

Page 87: ...0 500 00 rpm bar 8 00 0 01 Run F3 13 Integral time 1 0 0 999 ms 80 1 Run F3 14 Integral time 2 0 0 999 ms 0 1 Run F3 15 Integral time TI switch threshold 0 150 0 0 0 bar set to 0 the switching functio...

Page 88: ...me for Kd 1 0 999 ms 35 1 Run F3 38 Lower limit for I D 1 5 000 5 000 rpm 0 1 Run F3 39 System minimum speed 1 5 000 5 000 rpm 0 1 Run Tab 7 13 Controller parameter list Bosch Rexroth AG DOK SYTROX FC...

Page 89: ...roller ac cording to customer application After clicking p Q control the main dialog will be switched to p Q control structure and the actual control parameters are shown and can be edited in this dia...

Page 90: ...white back ground see the figure shown as below The inactive group is shown with yellow background as read only To change this please change the group selection via drop down menu or via digital input...

Page 91: ...tor Control and Motor Parameter the maximal motor ac celeration and deceleration ramp limitation can be set DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 89 201 Frequency controlled pump drive system...

Page 92: ...3 l For small oil volume for example oil volume 3 l F3 10 Pressure up filter time can be set to be in the range of 40 80 ms And F3 11 Pressure down filter time can be a little bit smaller than F3 10 i...

Page 93: ...depending on the overall oil volume in the system With small oil volume only a small P gain is possible If the over shoot is too big or there are vibrations reduce Kp in steps of 2 Fig 7 22 Effect of...

Page 94: ...ed to improve the sys tem performance Differential gain D gain E3 16 Kd D gain F3 16 works like a damping If there is a big overshoot in the system then increase this value in steps of 0 1 up to 1 0 H...

Page 95: ...creased if over voltage or over current error happens during deceleration recommendation value is 0 3 2 according to application normally a constant pressure system will not get over voltage error wi...

Page 96: ...vation of the parameter selec tion mode Activation of free selectable parameter sets The parameter sets can be activated and switched via the digital input which has been set to p Q parameter selectio...

Page 97: ...the FcP 5020 software is using the first set of parameters set 0 Configuration of the parameter set values 2 sets parameters can be set through following parameter list Parameter Set x Set 0 Set 1 Pre...

Page 98: ...switching func tion is invalid when the setting is 0 0 0 0 Run F3 33 Integral time TI_1 1 0 999 ms 80 Run F3 34 Integral time TI_2 1 0 999 ms 0 Run F3 35 Integral time TI switch threshold 1 150 0 0 0...

Page 99: ...ion Working principle During the operation the flow command which is lower than the minimum flow limitation is set to the minimum flow value and the pressure command which is lower than the minimum pr...

Page 100: ...Pump power limitation or Master to slave will be open see the figure shown as below There is no control word for the sleep function it works au tomatically if the working condition satisfies the thres...

Page 101: ...or multi pump working as a group to achieve a larger flow In this application a master converter is needed to control the speed flow of slave pumps DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 99 201...

Page 102: ...and 0 999 ms 4 1 Run F4 03 Pump function control word 0 31 Bit0 Pump power limit Bit1 Pump thermal protection Bit2 Switch master to slave Bit3 Two points double pump Bit4 Pressure drop overshoot compe...

Page 103: ...0 1 Run E5 19 Wake up level 0 0 100 0 0 0 0 1 Run E5 20 Wake up delay 0 2 60 0 s 0 5 0 1 Run Tab 7 18 Parameter list of sleep wake function The frequency converter may go into the sleep mode when all...

Page 104: ...p boost E5 18 x Pressure command value During sleeping the frequency converter monitors the actual PID feedback and wakes up when the following two conditions are met PID feedback Pressure command val...

Page 105: ...ar 10 0 0 1 Stop F4 34 Speed switching threshold adjustment 0 1 1 0 0 9 0 1 Stop Tab 7 19 Parameter list of two points double pump control Choose different pump type and logic according to the type of...

Page 106: ...ly reverse output signal through relay it does not influence the control parameter switching Application example 24V power supply normal open relay terminal Ta Tb and Rexroth two points pump controlle...

Page 107: ...compen sation 0 0 1 000 0 bar 0 0 0 1 Run F4 46 Pressure reduce for overshoot compensation 1 000 0 0 0 bar 0 0 0 1 Run Tab 7 20 Parameter list of pressure drop overshoot compensation Set control bit b...

Page 108: ...ation function can be activated via bit0 of F4 03 The real time pump power can be calculated from pressure feedback the ac tual speed and pump displacement If the calculated pump power output ex ceeds...

Page 109: ...ed to reduce the p Q command and acceleration during start up period to minimize the too high of acceleration or potential over current condition during start up Once this function is active set F4 20...

Page 110: ...this function see the figure shown as below Each function in this window begins with a selection box the function is ac tive if this box is selected and the function works exactly as the dialog text...

Page 111: ...n Attri F4 00 Protection function control word 0 15 Bit0 Pressure sensor failure PSF Bit1 Actual pressure monitoring Bit2 p Q max command limit Bit3 Oil changing detection 0 Run F4 06 Pressure sensor...

Page 112: ...ated via bit0 of F4 00 It works in three different phases Motor runs in negative direction of rotation Once motor runs in negative direction this function will check if the mo tor speed is consistentl...

Page 113: ...ack keeps dropping with decreasing rate higher than 1 F4 11 bar s if the pressure drops slower than this rate consistently for 2x F4 11 seconds a failure for sensor defect will be signalled Fig 7 38 P...

Page 114: ...7 24 Parameter list of pressure over limit detection The detection of pressure feedback can be activated via bit1 of F4 00 F4 15 When the feedback pressure goes beyond F4 15 bar for F4 17 s the warni...

Page 115: ...ration time 0 1 0 Run Tab 7 25 Parameter list of oil change warning error function Oil change monitoring function can be activated by Bit3 of F4 00 Oil operation time will be counted and saved in F4 5...

Page 116: ...imum pressure and flow command limitation F4 21 and F4 23 works all the time independently to any control bit That means if the setting pres sure or flow command is lower than F4 21 or F4 23 it will b...

Page 117: ...required for the pump cooling may not be adequate The pump thermal protection function will detect if pump speed is lower than the speed limitation F4 36 and trig ger warning or error message accordin...

Page 118: ...input to be selected see op tion 6 16 in the table above Most of these options can be clarified by name the others are described below 6 Oil filter warning and 9 Oil filter error for oil filter warnin...

Page 119: ...20 to 1 3 parameter listed in the table above will be changed to Cy troPac default setting Set F1 20 to 0 will NOT bring the converter back to FcP status for details please reference Restore ASF Param...

Page 120: ...With active CytroPac functionality the output is automatically configures to control the LED flash function For normal status the light is always green for warning condition the light will flash betwe...

Page 121: ...ng range FcP default myCro default F1 04 Pressure command selection 0 Pressure command digital setting 0 1 Pressure command digital setting 1 2 Pressure command digital setting 2 3 Pressure command di...

Page 122: ...6 DO1 output 0 No function assigned from ASF 1 Converter warning 2 Green CytroPac flashing LED 3 Red CytroPac flashing LED 4 Oxygen too high for myCro 5 Pressure too low for myCro 1 4 F2 37 EDO output...

Page 123: ...Warning type 0 10 See chapter 7 10 8 Monitor ing Parameter on page 143 11 Oxygen too high 12 System pressure too low E0 01 First run command source 0 Panel 1 Multi function digital input 2 Communicat...

Page 124: ...d EAI input U1 10 Stop monitoring display 0 99 2 Setting fre quency 33 I O card EAI input Tab 7 32 Different parameter list between myCro and FcP default setting Bosch Rexroth AG DOK SYTROX FCP5020 IT...

Page 125: ...ge Warning 1 oxygen too high Converter raises warning message if oxygen feedback is higher than F4 72 for F4 73 hours Warning index will be shown via displaying pa rameter d0 88 11 and this also set a...

Page 126: ...codes can be achieved through reading and writing of the contents in frequency converter parameter registers via communication The characteristics and scope of reading and writing function codes are i...

Page 127: ...3 p Q parameter group 0 Parameter group 0 1 Parameter group 1 7 6 Pressure command digital selection 00 F1 05 Pressure command 0 01 F1 06 Pressure command 1 10 F1 07 Pressure command 2 11 F1 08 Press...

Page 128: ...n Profibus DP H1 10 Output PZD 1 1 H0 00 EFC control word H1 11 Output PZD 2 4 F0 20 Pressure command H1 12 Output PZD 3 5 F0 21 Flow command H1 13 Output PZD 4 6 F0 22 Reserved H1 30 Input PZD 1 1 H0...

Page 129: ...88 ASF warning type 6 d0 89 ASF error type H3 31 MEP List of Output Process Data 0 H0 00 EFC control word 1 F0 20 Pressure command 2 F0 21 Flow command 3 F0 22 Reserved CANopen Sercos III EtherCAT FcP...

Page 130: ...f iron Fe 450 J kg Cv of aluminum Al 900 J kg M Motor weight kg Fig 7 44 Motor thermal protection time constant Increase the value of C1 74 Motor thermal model protection time constant appropriately i...

Page 131: ...1 analog input 2 AI2 analog input 3 EAI analog input 0 Stop E2 25 AO1 output mode 0 0 10 V 1 0 20 mA 1 Run E2 26 AO1 output setting 0 Output frequency 1 Setting frequency 2 Output current 4 Output vol...

Page 132: ...ngineering Software IndraWorks which has the function up and down load parameter from converter remote control diagnostics and monitoring After this software has been installed on PC Rexroth EFC Conve...

Page 133: ...Parameter attribute Run Parameter setting can be modified when the converter is in run or stop status Stop Parameter setting can only be modified when the converter is in stop status Read Parameter s...

Page 134: ...command digital setting 2 3 Pressure command digital setting 3 0 Run F1 05 Pressure command digital setting 0 0 0 1 000 0 bar 10 0 0 1 Run F1 06 Pressure command digital setting 1 0 0 1 000 0 bar 10...

Page 135: ...Stop F1 20 CytroPac parameter initialization 0 No selection 1 CytroPac basic 2 CytroPac advanced 3 CytroPac premium 4 myCro 0 Stop F1 21 CytroPac parameter display 0 No selection 1 CytroPac basic 2 Cy...

Page 136: ...top F2 07 Pressure feedback null offset in V or mA 0 0 5 0 V mA 4 0 mA 0 1 Stop F2 08 Flow command corresponding to 5V 10V or 20mA 1 5 000 rpm 400 1 Stop F2 09 Flow command null offset in V or mA 0 0...

Page 137: ...Stop F2 20 X5 input 0 Stop F2 21 EX1 input 0 Stop F2 22 EX2 input 0 Stop F2 23 EX3 input 0 Stop F2 24 EX4 input 0 Stop F2 31 AO1 output 0 No function assigned from ASF 1 Pressure command scaled by F2...

Page 138: ...command F2 31 2 Pressure feedback F2 31 3 Setting speed F2 31 4 Output speed Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 136 201 Frequency controlled pump drive system Sytronix FcP 5020 Commissionin...

Page 139: ...001 Run F3 17 Filter time for Kd 0 0 999 ms 35 1 Run F3 18 Lower limit for I D 0 5 000 5 000 rpm 0 1 Run F3 19 System minimum speed 0 5 000 5 000 rpm 0 1 Run F3 30 Filter time for pressure ascending...

Page 140: ...10 0 0 1 Stop F4 10 Pressure sensor detection threshold standby 1 0 1 000 0 bar 5 0 0 1 Stop F4 11 Pressure sensor detection period standby 0 1 100 0 s 1 0 0 1 Stop F4 15 Maximum system pressure warni...

Page 141: ...45 Pressure boost for drop compensation 0 0 1 000 0 bar 0 0 1 Run F4 46 Pressure reduce for overshoot compen sation 1 000 0 0 0 bar 0 0 1 Run F4 50 Oil filter warning error delay time 0 1 000 s 60 1 R...

Page 142: ...d reverse 1 Forward only 2 Reverse only 3 Swap default direction 3 Stop E0 26 Acceleration time 0 1 6 000 0 s 0 5 0 1 Run E0 27 Deceleration time 0 1 6 000 0 s 1 0 0 1 Run E1 01 X2 input 0 46 34 Stop...

Page 143: ...oPac advanced CytroPac advanced comm E0 17 Direction control 3 1 1 1 E1 61 Broken wire protec tion 0 2 2 2 E2 15 Relay1 output selec tion 14 15 15 15 F1 03 Pressure command source 0 3 F1 11 Flow comma...

Page 144: ...via F1 20 Commissioning of other parameters CytroPac setting switches to FcP default via F1 00 Set F1 20 to 0 will NOT change any other parameter Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 142 201...

Page 145: ...emperature warning 7 Oil change warning 8 Reserved 9 Pump thermal protection warning 10 Pump power limitation warning 11 Oxygen too high 12 System pressure too low d0 89 Error type 0 No error 1 Pressu...

Page 146: ...Default Min Attri b0 00 Access authority setting 0 Basic parameters 1 Standard parameters 2 Advanced parameters 3 Start up parameters 4 Modified parameters 0 Run b0 09 Parameter initialization settin...

Page 147: ...400 VAC 600 785 V 770 C0 27 Stall overcurrent prevention level 20 0 C2 42 150 0 0 1 Stop C0 28 Phase loss protection mode 0 3 3 Run C0 29 Converter overload pre warning level 20 0 200 0 110 0 0 1 Sto...

Page 148: ...ntage of frequency converter rated current Setting range of C0 25 0 Both disabled 1 Stall overvoltage protection enabled resistor braking disabled 2 Stall overvoltage protection disabled resistor brak...

Page 149: ...M 1 Stop C1 15 Torque constant 0 01 200 DOM 0 01 Run C1 20 Motor no load current 0 00 C1 07 A DOM 0 01 Stop C1 21 Stator resistance 0 00 50 00 DOM 0 01 Stop C1 22 Rotor resistance 0 00 50 00 DOM 0 01...

Page 150: ...boost DOM 0 1 Run C2 22 Automatic torque boost factor 0 320 50 1 Run C2 23 Heavy load stabilization setting 0 Inactive 1 Active 1 Run C2 24 Light load oscillation damping factor 0 5 000 0 1 Run C2 25...

Page 151: ...99 Inactive 0 Stop C3 42 Torque reference minimum value 0 0 C3 43 0 0 0 1 Run C3 43 Torque reference maximum value C3 42 200 0 150 0 0 1 Run C3 44 Torque positive limit 0 0 200 0 150 0 0 1 Run C3 45 T...

Page 152: ...Hz 1 Run with low limit frequency 0 Stop E0 16 Low speed frequency hysteresis 0 00 E0 10 Hz 0 00 0 01 Stop E0 17 Direction control 0 Forward Reverse 1 Forward only 2 Reverse only 3 Swap default direct...

Page 153: ...braking factor 1 00 1 40 1 10 0 01 Run E0 60 Jog frequency 0 00 E0 08 Hz 5 00 0 01 Run E0 61 Jog acceleration time 0 1 6 000 0 s 5 0 0 1 Run E0 62 Jog deceleration time 0 1 6 000 0 s 5 0 0 1 Run E0 70...

Page 154: ...uency setting second frequency setting Setting range of E0 06 0 Not saved when powered off or stopped 1 Not saved when powered off saved when stopped 2 Saved when powered off not saved when stopped 3...

Page 155: ...emperature sensor channel 0 Inactive 1 AI1 analog input 2 AI2 analog input 3 EAI analog input 0 Stop E1 61 Broken wire protection 0 Inactive 1 Warning 2 Error 0 Stop E1 68 Analog input curve setting 0...

Page 156: ...command source activation 32 Error signal N O contact input 33 Error signal N C contact input 34 Error reset 35 Forward running FWD 36 Reverse running REV 37 Forward jog 38 Reverse jog 39 Counter inp...

Page 157: ...rve2 for AI1 curve1 for AI2 curve2 for pulse input 6 Curve1 for AI1 curve2 for AI2 curve2 for pulse input 7 Curve2 for AI1 curve2 for AI2 curve2 for pulse input DOK SYTROX FCP5020 IT01 EN P Bosch Rexr...

Page 158: ...Rated voltage 1P 200 240 VAC 220 1 Stop 3P 380 480 VAC 380 E2 50 Output curve 1 minimum 0 0 E2 52 0 0 0 1 Run E2 51 Output curve 1 minimum value 0 00 100 00 0 00 0 01 Run E2 52 Output curve 1 maximum...

Page 159: ...rvoltage 11 Converter overload pre warning 12 Motor overload pre warning 13 Converter stop by external error 14 Converter error 15 Converter OK 16 Counter target value arrival 17 Counter middle value...

Page 160: ...ge protection threshold 0 0 100 0 50 0 0 1 Run E5 09 Pump leakage protection delay 0 0 600 0 s 0 0 Inactive 0 0 0 1 Run E5 10 Pump leakage protection delay at start up 0 0 600 0 s 60 0 0 1 Run E5 15 S...

Page 161: ...1 200 bps 1 2 400 bps 2 4 800 bps 3 9 600 bps 4 19 200 bps 5 38 400 bps 3 Stop E8 11 Modbus data format 0 3 0 Stop E8 12 Modbus local address 1 247 1 1 Stop E8 13 Modbus level edge sensitivity selecti...

Page 162: ...d last detailed error type 00000 FFFFF 0 Read Value range of E9 05 E9 07 0 No error 1 OC 1 overcurrent at constant speed 2 OC 2 overcurrent during acceleration 3 OC 3 overcurrent during deceleration 4...

Page 163: ...dP internal parameter error 50 idE converter internal error 51 OCd extension card internal error 52 OCc extension card PDOs configuration error 54 PcE remote control communication error 55 PbrE parame...

Page 164: ...d F0 06 ASF trial time left 0 65 535 Read F0 07 ASF API version Read F0 10 ASF status 0x0000H 0xFFFFH 1 Read F0 20 ASF Command 1 0 Read F0 21 ASF Command 2 0 Read F0 22 ASF Command 3 0 Read F0 23 ASF...

Page 165: ...version 0 01 Read H0 19 Opt 2 active interface version 0 01 Read H0 20 Extension card 1 type 0 None 1 PROFIBUS card 2 CANopen card 3 Multi Ethernet card 8 I O card 9 Relay card 0 Read H0 30 Extension...

Page 166: ...PO4 5 PPO5 6 PPO6 7 PPO7 8 PPO8 Read H1 10 Output PZD 1 0 Not used 1 Control word 2 Frequency command 3 Torque command 1 1 Stop H1 11 Output PZD 2 2 1 Stop H1 12 Output PZD 3 0 1 Stop H1 13 Output PZD...

Page 167: ...1 Stop H1 36 Input PZD 7 0 1 Stop H1 37 Input PZD 8 0 1 Stop H1 38 Input PZD 9 0 1 Stop H1 39 Input PZD 10 0 1 Stop Output PZD 1 Output PZD 10 are the process data con tainers for data transferring fr...

Page 168: ...1 Run H8 16 Input curve 0 minimum frequency E0 09 E0 09 Hz 0 00 0 01 Run H8 17 Input curve 0 maximum H8 15 120 0 100 0 0 1 Run H8 18 Input curve 0 maximum frequency E0 09 E0 09 Hz 50 00 0 01 Run H8 2...

Page 169: ...vation 20 Frequency Up command 21 Frequency Down command 22 Up Down command reset 23 Torque Speed control switch 25 3 wire control 26 Simple PLC stop 27 Simple PLC pause 30 Second frequency setting so...

Page 170: ...e 10 Converter undervoltage 11 Converter overload pre warning 12 Motor overload pre warning 13 Converter stop by external error 14 Converter error 15 Converter OK 16 Counter target value arrival 17 Co...

Page 171: ...onverter running 2 Converter DC braking 3 Converter running at zero speed 4 Speed arrival 5 Frequency level detection signal FDT1 6 Frequency level detection signal FDT2 7 Simple PLC stage complete 8...

Page 172: ...Setting speed 4 User defined setting speed 5 User defined actual speed 10 Output voltage 11 Output current 12 Output power 13 DC bus voltage 14 Energy saving counter kWh 15 Energy saving counter MWh...

Page 173: ...rtugal 7 Italian 8 Korean 0 Stop U2 09 Permanent monitoring 0 99 0 Run U2 10 Run monitoring items 1 0 Run U2 20 Stop monitoring items 1 0 Run U2 11 Run monitoring items 2 0 100 2 Run U2 12 Run monitor...

Page 174: ...AO output 40 Digital input 1 43 I O card digital input 45 DO1 output 47 I O card EDO output 50 Pulse input frequency 55 Pulse output frequency 60 Relay output 62 I O card relay output 63 Relay card ou...

Page 175: ...99 Firmware version 100 Inactive DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 173 201 Frequency controlled pump drive system Sytronix FcP 5020 Commissioning of Sytronix FcP 5020 System...

Page 176: ...quency 1 kHz d0 23 Power stage running time 1 h d0 30 AI1 input 0 01 V 0 01 mA d0 31 AI2 input 0 01 V 0 01 mA d0 33 I O card EAI input 0 01 V 0 01 mA d0 35 AO1 output 0 01 V 0 01 mA d0 37 I O card EAO...

Page 177: ...rsion 0 01 EFC parameter information according to EFC firmware version 03V18 there could be deviations from actual firmware version DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 175 201 Frequency cont...

Page 178: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 176 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 179: ...ough control panel communication or engineering soft ware If the standard parameterization is insufficient for your application contact the responsible Bosch Rexroth account manager 8 2 2 Operating Mo...

Page 180: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 178 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 181: ...e Material number Documentation type Rexroth Sytronix FcP50xx 70xx Motor Pump Unit MPES21 R911342715 Operating instructions Rexroth Sytronix Motor Pump Unit MPES2 PGF PGH MOT FC1 R911345047 Mounting i...

Page 182: ...to a standstill in a controlled form using the machine control commands Switch off the power and control voltage of the controller Switch off the protective motor switch for the fan unit Depressurize...

Page 183: ...arge before accessing an electric component Measure the elec trical voltage of live parts before beginning to work to make sure that the equipment is safe to touch 3 Disconnect all electrical connecti...

Page 184: ...R911345048 Mounting instructions 1 This documentation contains references to supplementary doc umentation for the individual components motors pumps hy draulic fluid etc Tab 11 1 Documentation motor p...

Page 185: ...domicile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Strasse 2 97816 Lohr am Main Germany Packaging The packaging materials consist of cardboard woo...

Page 186: ...stics can contain flame retardants These plastic parts are labeled according to EN ISO 1043 They have to be recycled separately or disposed of according to the valid legal requirements Bosch Rexroth A...

Page 187: ...this means you are changing the condition of the product as supplied Any statements made by Bosch Rexroth regarding this product will then become invalid If you have any questions please contact your...

Page 188: ...Bosch Rexroth AG DOK SYTROX FCP5020 IT01 EN P 186 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 189: ...Ar2 Parameter set switching from set 1 to set 2 14 3 EFC Warning Code Code Description P oFF Displayed only at power down drop in stop state S Err Parameter change blocked C dr Communication disconnec...

Page 190: ...tion time E0 26 reduce sudden load change Running command active while motor is coasting Restart after motor stop or start with speed capture E0 35 Wrong setting of V f curve related parame ters Adjus...

Page 191: ...son Solution Surge voltage from power supply Check input power supply Motor to earth short circuit causes DC bus capacitors overcharged Check motor connection Excessive load rotation inertia Use suita...

Page 192: ...verter outputs Check the connections of frequency converter outputs re move omitted or broken connections Imbalance in the three phases of outputs Check motor 14 4 12 Error 12 ESS Soft Start Error Pos...

Page 193: ...Temperature detection circuit error Contact with service 14 4 15 Error 22 UH Converter under Temperature Possible reason Solution Ambient temperature is lower than 10 C Provide a reasonable ambient te...

Page 194: ...situations 14 4 20 Error 31 Ot Motor over Temperature Possible reason Solution Excessive load or bad cooling Check load Provide a better cooling condition Temperature sensor defect Check the motor te...

Page 195: ...put signals via external terminals Check external terminals status Wrong wiring setting of multi function external terminals Ensure the right external signals have been connected correctly to the righ...

Page 196: ...n Internal error caused by communication between control boards Contact with service 14 4 33 Error 49 idP Internal Parameter Error Possible reason Solution Internal error caused by parameter handling...

Page 197: ...ss Contact with service 14 4 40 Error 56 PrEF Parameter Restore Error after Firmware Update Possible reason Solution Error occurs if parameter settings cannot be restored after firmware update Contact...

Page 198: ...er value 4 Oil filter warning Oil filter almost full Clean or replace filter 5 Oil level warning Oil level too low Refill oil 6 Oil temperature warning Oil temperature reached Reduce hydraulic loses o...

Page 199: ...error Parameter setting repetition 1 Check if parameter settings are in conflict 2 EFC is under 24V mode switch mains supply on to avoid this 4 Oil filter error Oil filter full Clean or replace filte...

Page 200: ...fast and efficient way if you keep the following informa tion available Detailed description of the failure and the boundary conditions Information on the name plate of the products concerned particu...

Page 201: ...protection 183 Extension and Modification 185 F FcP 5020 ASF Type Code Description 38 FcP 5020 Parameter List 131 Fieldbus Communication 124 Frequency Converter Parameter Address 124 Frequency Convert...

Page 202: ...ion 10 Representation of Information Abbreviations 11 Representation of information Consistency 10 Representation of Information Safety In structions 10 Representation of Information Symbols 11 Requir...

Page 203: ...Notes DOK SYTROX FCP5020 IT01 EN P Bosch Rexroth AG 201 201 Frequency controlled pump drive system Sytronix FcP 5020...

Page 204: ...ectric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Phone 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics R912008034 R912008034 DOK SYTROX...

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