Industrial Hydraulics FAQs - dc-us.resource.bosch.com€¦ · RE 29016/01.12 VT-DFP. Hydraulics...

Industrial Hydraulics FAQs

Updated: AT_January2013

FAQ Title: VT-DFP(E) Identification Category: Electronics Sub-Category: Pump Electronics

Bosch Rexroth Corporation Hydraulics 2315 City Line Road Bethlehem, PA 18017 Tel (847) 645-3600

Question: Can you indentify VT-DFP… (VT-DFPE…)?

Answer: VT-DFP and VT-DFPE are pilot valves for DFE-pumps, like SYDFE1, SYDFEE, SYDFEN, SYHDFEE. See data sheet RE29016. If you do not stock a spare pump, at least keep a pilot valve on hand. This is especially recommended for model codes ending with a dash-number (like … -017). These are Special Order or SO-versions which can increase delivery time. After pilot replacement, the pump should be calibrated. See commissioning instructions, RE30011-B or RE30012-B. For additional assistance, contact the Service Department. Attachments: RE29016 RE30011-B RE30012-B

1/143/3 proportional directional valves direct operated, with electrical position feedback as pilot valves for control systems SY(H)DFE.

Type VT-DFP.

Component series 2XMaximum operating pressure 350 bar

RE 29016/01.12Replaces: 06.10

Type VT-DFPE-.-2X/... with integrated electronics

Type VT-DFP-.-2X/... with mating connector (separate order)

H6198H6633

Table of contentsContents PageFeatures 1Ordering code 2Technical data 4Electrical connection 6Unit dimensions 11Project planning information 13More information 13

Features– Pilot valve for the pressure and flow control system SY(H)DFE.– Actuation by means of a proportional solenoid with electri-

cal feedback– Control electronics: • VT-DFP for SY(H)DFE1 → external control

electronics VT 5041-3X • VT-DFPE for SY(H)DFEE → integrated, analog • VT-DFPC for SY(H)DFEC → integrated, digital with

CAN bus interface • VT-DFPn for Sytronix DFEn 5000 (SY(H)DFEn)

→ Integrated, digital with CAN bus interface, for variable-speed operation

2/14 Bosch Rexroth AG Hydraulics VT-DFP. RE 29016/01.12

Ordering code

VT-DFP - A - 2X / G24 K0 / 0 / V - *VT-DFPE - A - 2X / G24 K0 / 0 A 0 C / V - *VT-DFPC - A - 2X / G24 K0 / 0 A 0 C / V - *VT-DFPn - A - 2X / G24 K0 / 0 A 0 C / V - *

1 2 3 4 5 6 7 8 9 10 11

Series

1

Pilot valve for external electronics VT-DFPPilot valve with integrated analog electronics VT-DFPEPilot valve with integrated digital electronics VT-DFPCPilot valve with integrated digital electronics, variable-speed VT-DFPn

Spool design

2Standard (not for HFC fluids) A2-groove spool (for replacement purposes only) B4-groove spool (e.g. for HFC fluids) C

3 Component series 2X

4 Direct voltage 24 V G24

5 Connector (without mating connector) 1) K0

Installation orientation plug-in connector (VT-DFP) and/or integrated electronics (also see page 3)

6Radially to the pump axis 0Folded 90° in the direction of the subplate with counterclockwise direction of rotation 1Folded 90° in the direction of the subplate with clockwise direction of rotation 2

Additional functions: Closed-loop control A B C D R

7

VT-DFP (without)

VT-DFPE

Selectable pressure controller (high signal) ● APower limitation adjustable at the OBE valve ● BPower limitation adjustable via analog input ● CPressure controller that can be switched off (high signal) ● D

VT-DFPC Standard ● A

VT-DFPn Teach-In version for cyclic operation ● AReal-time version (speed calculation without Teach-In) ● R

Electronics assembly, option

8

VT-DFP (without)

VT-DFPE Standard electronics with leakage oil compensation ● - - ● 0Standard electronics without leakage oil compensation ● ● ● ● 1VT-DFPC Standard ● 0VT-DFPn Standard ● 0

Actual pressure value input(description of plug-in connectors on page 6)

Plug-in connector

9

VT-DFP (without)

VT-DFPEVT-DFPCVT-DFPn

Current input 4...20 mA X1 CVoltage input 0...10 V (standard) X1 VVoltage input 1...10 V X1 EVoltage input 0.5..5 V (Standard) 2) X2 F

10 FKM seals suitable for mineral oils (HL, HLP) according to DIN 51524 and HFC fluids 3) V

11 Further details in plain text, e.g. SO variant

● = available - = not available Preferred program

Hydraulics Bosch Rexroth AGRE 29016/01.12 VT-DFP. 3/14

Ordering code

Note on feature 6: Installation orientation of the valve electronicsClockwise direction of rotation, installation orientation 0

Clockwise direction of rotation, installation orientation 2

Counterclockwise direction of rotation, installation orientation 0

Counterclockwise direction of rotation, installation orientation 1

1) Connector dependent on the valve type (see "Technical data" and "Electrical connection")2) With the SY(H)DFEn control system with analog interfaces, the plug-in connector X2 cannot be used as actual pressure

value input. Thus, a separate pressure transducer has to be used and connected to plug-in connector X1 in this case.3) Only in connection with SYHDFE and spool design C (feature 2)

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Example of nameplate

1 Material number2 Serial number3 Date of manufacture4 Production order number5 Type designation


Technical data (For applications outside these parameters, please consult us!)

generalType VT-DFP VT-DFPE VT-DFPC VT-DFPnStorage temperature range °C –20 … +70 0 … +70 0 … +70 0 … +70Ambient temperature range °C –20 … +60 0 … +60 0 … +50 0 … +50Weight kg 1.96 2.25 2.25 2.25

hydraulicHydraulic fluid Mineral oil (HL, HLP) according to DIN 51524; HFC fluids

only in connection with SYHDFE control system and C spool design C (feature 2 of ordering code)

Hydraulic fluid temperature range °C –20 … +70Viscosity range mm2/s 20 … 380Maximum admissible degree of contamination of the hydraulic fluid according to ISO 4406 Class 18/16/13 (for particle size ≤ 4/6/14 μm)

Operating pressure Port A, P bar 350Port T bar 100

Ordering code: Accessories

Version 10/2011, enquire availability

Accessories for VT-DFP Material number Data sheetMating connector for solenoid plug R901017011 08006Mating connector for position transducer of valve R900023126 08006Compact power supply unit VT-NE32-1X R900080049 29929

Accessories for VT-DFPE, VT-DFPC and VT-DFPn Material number Data sheetMating connector 12-pin for central connection X1 without cable (assembly kit) R900884671 08006Mating connector 12-pin for central connection X1 with cable set 2 x 5 m R900032356Mating connector 12-pin for central connection X1 with cable set 2 x 20 m R900860399Test device VT-PDFE-1-1X/V0/0 for SY(H)DFEE and SY(H)DFEC R900757051 29689-BCompact power supply unit VT-NE32-1X R900080049 29929

Accessories for VT-DFPC and VT-DFPn only Material number Data sheetConverter USB/serial for laptops without serial interface VT-ZKO-USB/S-1-1X/V0/0

R901066684

Cable for connecting a WIN-PED PC (RS232) to the X2 interface Length 3 m

R901156928

T connector for the simultaneous connection of a WIN-PED PC (RS232) and use of the input at plug-in connector X2

R901117164

Mating connector for interface X3, M12, straight, can be connected independently 5-pin, shielded, A-coded, cable diameter 6...8 mm R901076910


electricType VT-DFP VT-DFPE VT-DFPC VT-DFPn

Control

External control elec-

tronics VT 5041-3X

Integrated, analog

Integrated, digital

Integrated, digital

Operating voltage UB

See data sheet 30242

24 VDC+40 % –5 %

24 VDC+40 % –5 %

24 VDC+40 % –5 %

Operating range (short-time operation)Upper limit UB(t)max 35 VLower limit UB(t)min 21 V

Current consumption (in static control operation)Rated current INominal 0.6 AMaximum current Imax 1.25 A

Inputs

Actual pressure value inputX1; pin 10 and 11

U or I Determination by means of

ordering code

Parameterizable:0...20 mA; 4...20 mA; 0...10 V;0…5 V; 0.5…5 V; 0.1...10 V;

1...10 VAnalog current inputs, load RB 100 Ω 100 Ω 100 ΩAnalog voltage inputs RE ≥ 50 kΩ ≥ 100 kΩ ≥ 100 kΩDigital inputs Logic 0 ≤ 0.6 V ≤ 8 V ≤ 8 V

Logic 1 ≥ 21 V ≥ 14 V ≥ 14 V

Outputs

ncommand / pactual / UOUT1 1) UAImax

0 … 10 V1.5 mA

±10 V2 mA

±10 V2 mA

αactual / UOUT2 2) UAImax

±10 V1.5 mA

±10 V2 mA

±10 V2 mA

Digital outputs Logic 0 Ua < 1 VLogic 1 Ua ≥ UB – 5 V; 10 mA (short-circuit-proof)

Solenoid coil resistance Ω 2.1 ... 3.2Coil resistance position transducer at 20 °C

Between port 1 and 2 Ω Approx. 113Between port 3 and 4 Ω Approx. 101

Electrical connection See page 6See

page 7See

page 8See

page 9Protection class according to EN 60529 IP 65 with mounted and locked plug-in connectors

Technical data (For applications outside these parameters, please consult us!)

Notice:For information on the environment simulation testing for the areas of EMC (electro-magnetic compatibility), climate and me-chanical load, see data sheet 30030-U.

1, 2) With VT-DFPC and VT-DFPn, the outputs are parameterizable, condition as supplied see pages 8/9

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Electrical connection: Type VT-DFP... (for external analog electronics)

SolenoidMating connector 3-pin Z4 M SW according to DIN EN 175301-803(separate order, see page 4)

Connection to connector

Connection to mating connector

to the amplifier

Inductive position transducer

Coil connection ConnectorConnection to plug-in connector (view on installation side)

Signal

Reference

Feed-in

Shield

Amplifier

Mating connector 4-pin Pg7-G4W1F/Pg7 SW(separate order, see page 4)

Details on the electrical connection to the VT 5041-3X amplifier are described in data sheet 30242.

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Electrical connection: VT-DFPE... (with integrated analog electronics)

X1: Central connectionMating connector according to EN 175201-804 (12-pin), ordering code see section Accessories on page 4

X2: Connection of pressure transducer HM 16 (mating connector M12)

Top view on mating connector

Pin Signal HM 16 Pin1 OUT, +UB 2 n.c.3 Reference L04 IN, analog, 0.5 to 5 V DC 5 n.c.

Allocation of connector or mating connector and cable set

Pin Signal Description Signal direction Type of signalAllocation in the cable set (accessories)

1 +UB Voltage supply IN 24 V DC 1 Supply line 3 x 1.0 mm²

2 0 V = L0 Reference potential for the voltage supply - 2PE Earth Earthing connection for the electronics - Green/Yellow

3 Fault Signals failures, e.g. cable break command / ac-tual values, controller monitoring (logic 0 = error) OUT Logic 24 V White

Supply line 10 x 0.14 mm² shielded (one end of the shield must be connected to the control!)

4 M0 Reference potential for analog signals - Yellow5 α command Swivel angle command value IN Analog ±10 V Green6 α actual Actual swivel angle value normalized OUT Analog ±10 V Violet7 pcommand Pressure command value IN Analog 0...10 V Pink8 pactual Actual pressure value normalized OUT Analog 0...10 V 1) Red

9 Function depends on electronics type and addi-tional function, see below Brown

10 Actual pres-sure value H Actual pressure value input: Signal level de-pends on feature 14 of the ordering code With type "F" (0.5...5 V) reserved

IN Analog Black

11 Actual pres-sure value L - Analog Blue

n.c. Gray

Functions at pin 9

Pin Additional functionFunction dependent on feature 7 of the ordering code (see page 2) Signal direction Type of signal

9

-..A… Switching to different oil volume adjustment (switch TD) IN Logic 24 V-..B… Power limitation active OUT Logic 24 V-..C… Command value of power limitation IN Analog 0...10 V-..D… Switch off pressure controller IN Logic 24 V

1) When using a pressure transducer with raised zero point (e. g. (4... 20 mA), a voltage of -1...-2.5 V will be output in the event of a cable break.

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Electrical connection: VT-DFPC... (with integrated digital electronics)

X2: Connection of pressure transducer HM 16 and serial interface RS232 (mating connector M12)


Pin Signal Description Signal directionType of signal

Allocation in the cable set (accessories)





4 M0 Reference potential for analog signals - Yellow

5 AI2 Analog input AI2Standard: Swivel angle command value IN Analog ±10V Green

6 UOUT2Analog outputStandard: Actual swivel angle value normalized OUT Analog ±10V Violet

7 AI1 Analog input AI1Standard: Pressure command value IN Analog 0...10 V Pink

8 UOUT1Analog outputStandard: Actual pressure value normalized OUT Analog ±10 V Red

9 DI1 Digital input DI1 IN Logic 24 V Brown

10 Actual pres-sure value H Actual pressure value input: Signal level de-pends on feature 14 of the ordering code

IN Analog Black


n.c. Gray


X3: Connection CAN bus and digital input 2 (DI2) (connector M12)

Top view connector

Pin Signal HM 16 Pin Signal RS2321 OUT, +UB 2 RxD3 Reference L04 IN, analog, 0.5 to 5 V DC 5 TxD

Top view mating connector

Pin Signal input Pin Signal CAN1 n.c. 3 CAN GND2 IN, digital IN2 (DI2) 4 CAN-HIGH

5 CAN-LOW

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Electrical connection: VT-DFPn... (with integrated digital electronics)

X2: Serial interface RS232 and a switchable digital input S1/pressure transducer input for HM 16 (mating connector M12)

Top view mating connector

Pin Signal input Pin Signal RS2321 OUT, +UB 2 RxD3 Reference L04 Analog input 0.5...5 V for HM 16 or

Digital input 0 V low, 10 V high (max. 12 V)Dependent on additional function (feature 7 of the ordering code):– Teach-In version: Digital input "Variable-speed operation on, S1"– Real-time version: Input as analog input for pressure transdu-

cer HM 16

5 TxD


Pin Signal Description Signal direction Type of signalAllocation in the cable set (accessories)





4 M0 Reference potential for analog signals - Yellow

5 AI2Analog input AI2Standard: Swivel angle command value

IN Analog ±10 V Green

6 UOUT2Analog outputStandard: Actual swivel angle value normalized

OUT Analog ±10V Violet

7 AI1Analog input AI1Standard: Pressure command value

IN Analog 0...10 V Pink

8 UOUT1Analog outputStandard: Speed command value

OUT Analog ±10 V Red

9 DI1

Digital input DI1Dependent on additional function (feature 7 of the ordering code):– Teach-In version: Synchronization bit DI1– Real-time version: Activate real-time operation

IN Logic 24 V Brown

10 Actual pres-sure value H Actual pressure value input: Signal level de-pends on feature 9 in the ordering code

IN Analog Black


n.c. Gray



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Top view connector

Pin Signal input Pin Signal CAN1 n.c. 3 CAN GND2 IN, digital IN2 (DI2)

Dependent on additional function (feature 7 of the ordering code):– Teach-In version: Start Teach-In, S2– Real-time version: Manual speed provision active, speed is ap-

plied according to the real-time operation status and the setting of the R parameters.

4 CAN-HIGH

5 CAN-LOW

X3: CAN bus and digital input 2 (connector M12)

Electrical connection: VT-DFPn... (continued)


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Rzmax 4

0,01/100


Unit dimensions (dimensions in mm)Type VT-DFP...2X/...

Type VT-DFPE...2X/...

Item explanation see page 12

Required surface quality of the valve contact surface

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Unit dimensions (dimensions in mm)

Type VT-DFPC...2X/... and VT-DFPn...2X/...

1 Valve housing2 Proportional solenoid with position transducer

3a Mating connectors for solenoid and position transducer (separate order see page 4)

3b Mating connector for connector X1 (separate order see page 4)

4 Space required for removing the mating connector5 Identical seal rings for ports P, A, and T6 Solenoid rotated by 90° (installation orientation "2")7 Connection swivel angle position sensor (rotary angle

sensor VT-SWA-1-1X)8 Name plate9 Integrated electronics

10 Mating connector X2 for connecting a pressure trans-ducer HM 16 (only with VT-DFPE./...F, VT-DFPC... and VT-DFPn)

11 Mating connector X3 for connecting the CAN bus (only with VT-DFPC... and VT-DFPn)

12 Space required for plug-in connection (HM 16)

13 Dimension for version VT-DFPE...F, VT-DFPC and VT-DFPn (connection for HM 16 or CAN bus)

14 Machined valve mounting face15 Space required for CAN connection (plug-in connec-

tion on the customer side)Valve mounting screws for all types:4 hexagon socket head cap screwsISO4762-M6X40-10.9-flZn-240h-L,Friction coefficient μtotal = 0.09 to 0.14 according to VDA 235-101,Tightening torque MA = 7 Nm,Material number: R913000058


Project planning information

Supplementary notes on the SY(H)DFE control systems can be found in the operating instructions (see section "More informa-tion about this control system" on this page.).

More information on control systems SY(H)DFE

Operating instructions for SY(H)DFE1 30011-BOperating instructions for SY(H)DFEE 30012-BOperating instructions for SY(H)DFEC 30027-B Operating instructions for SY(H)DFEn 30014-BData sheet for SYDFE.-2X 30030Data sheet for SYDFEn-2X 62240Data sheet for SYDFE.-3X 30630Data sheet for SYDFEn-3X 62241Data sheet for SYHDFE.-1X 30035Data sheet for SYHDFEn-1X 62242Data sheet for external control electronics VT 5041-3X for SYDFE1 30242Data sheet for swivel angle sensor VT-SWA-1-1X 30268Data sheet for pressure transducer HM 12-1X and HM 13-1X 29933Data sheet for pressure transducer HM 16-1X 30266Data sheet for pressure transducer HM 17-1X 30269Operating instructions for test device VT-PDFE 29689-BCurrent information is also available on the Internet under the address http://www.boschrexroth.com/sydfe (English) or http://www.boschrexroth.de/sydfe (German).

Bosch Rexroth AGHydraulicsZum Eisengießer 197816 Lohr am Main, GermanyPhone +49 (0) 93 52 / 18-0Fax +49 (0) 93 52 / 18-23 [email protected]

© This document, as well as the data, specifications and other informa-tion set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.The data specified above only serve to describe the product. No state-ments concerning a certain condition or suitability for a certain applica-tion can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.


Notes




Notes

RE 30011-B/05.12Replaces: 10.10English

Pressure and flow control systemSYDFE1 series 2X, 3X with external control electronics VT 5041-3X

Pressure/flow control system type SYDFE1 with external control electronics VT 5041-3X

Operating instructions

SYDFE1, series 3X

Valid for the following types:

VT 5041-3XSYDFE1, series 2X

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligationof own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth. It may not be reproduced or given to third partieswithout its consent.

An example configuration is shown on the title page. The delivered product may, therefore, differ from the product which is pictured.

The original operating instructions were created in the German language.

RE 30011-B/05.12 | SYDFE1 series 2X, 3X Bosch Rexroth AG 3/96

Contents

Contents1 About this document ................................................................................51.1 Validity of the documentation ......................................................................51.2 Required and supplementary documents ...................................................51.3 Representation of information .....................................................................62 Safety instructions ....................................................................................92.1 About this chapter .......................................................................................92.2 Intended use ...............................................................................................92.3 Improper use ...............................................................................................92.4 Personnel qualifications ............................................................................102.5 General safety instructions ........................................................................102.6 Product- and technology-related safety instructions .................................112.7 Personal protective equipment ..................................................................133 General notes on damage to material and the product .......................144 Delivery contents ....................................................................................155 Product description ................................................................................165.1 Performance description ...........................................................................165.2 Device description .....................................................................................165.3 Controller structure and basic operating modes .......................................195.4 Special operating modes ...........................................................................215.5 Operating pressure limits ..........................................................................255.6 Ambient conditions ....................................................................................275.7 Notes on the selection of hydraulic fluids ..................................................275.8 Noise level .................................................................................................285.9 Shaft variants ............................................................................................295.10 Spool variant of the VT-DFPE-x-2X pilot valve .........................................305.11 Functions of control electronics VT 5041-3X ............................................305.12 Master/slave operation ..............................................................................345.13 Identification of the product .......................................................................386 Transport and storage ............................................................................396.1 Transporting the SYDFE1 control system .................................................396.2 Storing the SYDFE1 control system ..........................................................417 Installation ...............................................................................................437.1 Unpacking .................................................................................................437.2 Installation conditions ................................................................................437.3 Installation positions and piping of SYDFE1 systems ...............................447.4 Installing the SYDFE1 control system .......................................................477.5 Connecting the SYDFE1 control system hydraulically ..............................497.6 Connecting the SYDFE1 control system electrically .................................528 Commissioning .......................................................................................598.1 Initial commissioning .................................................................................608.2 Recommissioning after standstill ...............................................................728.3 Running-in phase ......................................................................................729 Operation .................................................................................................7310 Maintenance and repair ..........................................................................7410.1 Cleaning and care .....................................................................................7410.2 Inspection ..................................................................................................7410.3 Maintenance ..............................................................................................7510.4 Repair ........................................................................................................7510.5 Spare parts ................................................................................................7611 Decommissioning ...................................................................................7812 Demounting and replacement ................................................................7812.1 Required tools ...........................................................................................7812.2 Preparing demounting ...............................................................................7812.3 Demounting the SYDFE1 control system ..................................................7812.4 Preparing the components for storage or further use ...............................79

4/96 Bosch Rexroth AG SYDFE1 series 2X, 3X | RE 30011-B/05.12

13 Disposal ...................................................................................................7913.1 Environmental protection ..........................................................................7914 Extension and conversion .....................................................................7915 Troubleshooting ......................................................................................8015.1 How to proceed for troubleshooting ..........................................................8415.2 Malfunction table .......................................................................................8516 Technical data .........................................................................................8917 Annex .......................................................................................................9017.1 Address directory ......................................................................................9017.2 Position of adjustment elements of control electronics VT 5041-3X .........9117.3 Block circuit diagram of VT 5041-3X ........................................................9218 Alphabetical index ..................................................................................94


About this document

1 About this document

1.1 Validity of the documentationThis documentation is valid for the following products:

• SYDF1n series 2X • SYDFE1 series 3X

This documentation is intended for engineers, fitters, operators, service technicians and plant operators.These instructions contain important information on the safe and appropriate installation, transport, commissioning, maintenance, disassembly and simple troubleshooting of the pressure and flow control systems SYDFE1 series 2X and 3X.

f Read these instructions completely, especially Chapter 2 “Safety instructions“ on page 9, before working with the SYDFE1 control system.

1.2 Required and supplementary documents f Only commission the product, when you have the documents marked with the

book symbol at hand and have understood and observed them.

Table 1: Required and supplementary documentsTitle Document no. Type of documentOrder confirmation Contains the pre-set

technical data of your pressure/flow control systemSYDFE1

Installation drawing Contains the outer dimensions, all ports and the hydraulic circuit diagram of your pressure/flow control system SYDFE1

General operating instructions for axial piston units

RE 90300-B Operating instructions

Pressure and flow control system SYDFE1..2X, SYDFEE..2X, SYDFEC..2X, SYDFEn..2X

RE 30030 Data sheet

Pressure and flow control system SYDFE1, SYDFEE, SYDFEC, SYDFEn

RE 30630 Data sheet

Axial piston variable displacement pump A10VSO series 31, sizes NG18 to 140

RE 92711 Data sheet

Axial piston variable displacement pump A10VSO series 32, sizes 45 to 180

RE 92714 Data sheet

External control electronics for the SYDFE1 control of the A10VSO axial piston variable pump, type VT 5041-3X/...

RE 30242 Data sheet

External control electronics (variant) for the SYDFE1 adjustment of the axial piston pump A10VSO

RD 30242-01 Datenblatt


About this document

Title Document no. Type of document3/3 proportional directional valves direct operated, with electrical position feedback, as pilot valve for control systems SY(H)DFE, type VT-DFP

RD 29016 Datenblatt

Axial piston units for use with HF fluids

RE 90223 Data sheet

Hydraulic fluids on a mineral oil basis for axial piston units

RE 90220 Data sheet

Pump pre-load valve for control system SYDFE, type SYDZ 0001-1X

RE 29255 Data sheet

Pressure transducers, types HM 12 and HM 13

RE 29933 Data sheet

Pressure transducer with integrated electronics, type HM 16

RE 30266 Data sheet

Pressure transducer with integrated electronics, type HM 17

RE 30269 Data sheet

Installation, commissioning and maintenance of hydraulic systems

RE 07900 Data sheet

Declaration on environmental compatibility

RE 30030-U Compliance data sheet

1.3 Representation of informationIn order that this documentation allows you to work directly and safely with your product, standardized safety notes, symbols, terms and abbreviations are used. For a better understanding, these are explained in the following sections.

1.3.1 Safety notesIn this documentation, safety instructions precede a sequence of activities whenever there is a risk of personal injury or damage to equipment. The precautions described to avoid these hazards must be observed.Safety instructions are set out as follows:

SIGnAl wORDType and source of hazardConsequences in the case of non-observance

f Measures to avert the hazard f

• warning symbol: draws attention to a hazard • Signal word: identifies the degree of hazard • Type and source of hazard: identifies the type or source of the hazard • Consequences: describes the consequences in the case of non-observance • Precautions: states, how the hazard can be avoided


About this document

Table 2: Hazard classes according to AnSI Z535.6-2006warning sign, signal word Meaning

DAnGER Indicates a hazardous situation which, if not avoided, will certainly result in death or serious injury. wARnInG Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTIOn Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE Damage to property: The product or the environment can be damaged.

1.3.2 SymbolsThe following symbols refer to notes, which are not relevant to safety, but increase the legibility of the documentation.Table 3: Meaning of symbolsSymbol Meaning

If this information is disregarded, the product cannot be used or operated in an optimum manner.

f Single, independent step of action1.

2.

3.

Numbered instruction for action:The numbers indicate that the activities are to be carried out consecutively.

1.3.3 Terms usedThe following terms are used in this documentation:Table 4: TermsDesignation MeaningA10VSO Axial piston variable displacement pump, open circuitA4VSO Axial piston variable displacement pump, open circuitHM12 Pressure transducerHM13 Pressure transducerIW9 Swivel angle sensor for the SYDFE1 control systemSYDFE1 Pressure/flow control system for external electronicsSYDFE1-2X Pressure/flow control system, series 2XSYDFE1-3X Pressure/flow control system, series 3XVT-DFPn Pilot valve with integrated, digital electronics, variable speedVT-DFP Pilot valve for SYDFE1VT 5041-3X External control electronics for SYDFE1


About this document

1.3.4 Abbreviations usedThe following abbreviations are used in this documentation:Table 5: AbbreviationsAbbreviation MeaningA/F Width across flats

EMC Electromagnetic compatibilityGND Ground

NG nenngröße (size)p Pressure (symbol)

P Power

pact Actual pressure value

pcomm Pressure command value

PCV Precompression VolumepDiff Control difference between pressure command value and

actual pressure valuePE Protective EarthPT Pressure TransducerRE Rexroth document in English languageSwitch TD Switching input for volume adjustment

SWA Swivel angle

SWAact Actual swivel angle value

SWAcomm Swivel angle command value

UB Supply voltage

US Unterspannung (undervoltage)VDE Verband der Elektrotechnik, Elektronik und Informationstechnik

(Association of electrical engineering, electronics and information technology)


Safety instructions

2 Safety instructions

2.1 About this chapterThe SYDFE1 control system has been manufactured according to the generally accepted rules of current technology. There is, however, still a risk of personal injury or damage to equipment if you do not observe this chapter and the safety instructions contained in this documentation.

f Read these instructions completely and thoroughly before working with the SYDFE1 control system.

f Keep this documentation in a location where it is accessible to all users at all times.

f Always pass the product together with the required documentation on to third parties.

2.2 Intended useThe product is electrical/hydraulic equipment.You may use the product as follows:

• for the electrohydraulic pressure and swivel angle control of an axial piston variable displacement pump

The SYDFE1 control system is technical equipment, which is not intended for private use.Intended use includes that you have read and understood these instructions completely, especially Chapter 2 “Safety instructions”.

2.3 Improper useAny use other than described in the section “Intended use” is considered as improper and is therefore not permitted.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 property. For this reason, use the product only in safety-relevant applications, if this use is expressly specified and allowed in this documentation. For example in explosion-protected areas or in safety-related parts of a control (functional safety).For damage resulting from improper use, Bosch Rexroth AG will not assume liability. The responsibility for risks arising from improper use lies exclusively with the user.Improper use of the product includes:

• if you do not adhere to the technical data, operating conditions and performance limits given in the data sheet and the order confirmation

• if you do not comply with national EMC regulations for the application at hand. If required, notes on proper installation in line with EMC regulations can be found in the EMC test documentation from Bosch Rexroth AG (compliance sheet RE 30030-U). The manufacturer of the system or machine is responsible for complying with the limit values stipulated in national regulations (European countries: EC Directive 2004/108/EC (EMC Directive); USA: See National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA) as well as regional engineering regulations;

• if you use the SYDFE1 control system in a potentially explosive atmosphere.


Safety instructions

2.4 Personnel qualificationsThe activities described in this documentation require basic knowledge of mechanics, electrics and hydraulics as well as knowledge of the associated technical terms. To ensure a safe use, these activities may therefore only be carried out by qualified personnel or under the direction and supervision of qualified personnel.Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures due to their professional training, knowledge and experience, as well as their understanding of the relevant conditions pertaining to the work to be done. Qualified personnel must observe the rules relevant to the subject area.

2.5 General safety instructions • Observe the valid regulations for accident prevention and environmental

protection. • Observe the safety regulations and rules of the country where the product is

used/operated. • Only use Rexroth SYDFE1 control systems in good technical order and

condition. • Observe all notes given on the product. • Persons who install, commission, operate, demount or maintain Rexroth

products must not consume any alcohol, drugs or pharmaceuticals that may affect their ability to respond.

• Only use accessory and spare parts released by the manufacturer in order to rule out personnel hazards arising from unsuitable spare parts.

• Adhere to the technical data and ambient conditions provided in the product documentation.

• If unsuitable products are installed or used in safety-relevant applications, unintended operational states can occur in these applications, which can cause personal injury and damage to property. Therefore, use the product only in safety-relevant applications, if this use is expressly specified and permitted in the documentation of the product.

• You may only commission the product when it has been established that the final product (for example, a machine or system), in which the Rexroth products are integrated, comply with national regulations, safety regulations and standards relevant for the application.


Safety instructions

2.6 Product- and technology-related safety instructions

wARnInGControl system falling down!SYDFE1 control systems are heavy. In the case of improper handling, they can fall down and cause severe injuries and crushing, because the parts can be, for example, sharp-edged, heavy, oily, loose or bulky.

f Transport the SYDFE1 control system using suitable lifting gear at the point provided for this purpose.

f Ensure a stable position while transporting the control system to the place of installation.

f Wear personal protective equipment when transporting the control system. f Observe national laws and regulations for accident prevention and safety at

work during transport.

Risk of injury caused by systems not shut down!Working on running systems poses a danger to life and limb. The work steps described in these operating instructions may only be performed on systems which were shut down. Before beginning work:

f Make sure that the drive motor cannot be switched on. f Make sure that all power-transmitting components and connections (electric,

pneumatic, hydraulic) are switched off according to the manufacturer’s instructions and are secured against being switched on again. If possible, remove the main fuse of the system.

f Ensure that the system is completely hydraulically relieved and depressurized. Please follow the system manufacturer’s instructions.

f Only qualified personnel (see Chapter 2.4 “Personnel qualifications” on page 10) are authorized to install the SYDFE1 control system.

lines under pressure!Risk of injury.

f Never disconnect, open or cut pressurized lines! f Before carrying out any installation or other work, depressurize the control

system.

High electrical voltage!Risk of death and risk of injury from electric shock.

f Before starting installation work, plugging and unplugging connectors and carrying out any work, switch the control system off. Secure the electrical equipment against being switched on.

f Before switching the control system on, check the protective conductor on all electrical devices for proper connection according to the wiring diagram.


Safety instructions

wARnInGHigh noise emission during operation!The noise emission of SYDFE1 control systems depends, among others, on speed, operating pressure and the installation situation. Under normal operating conditions, the noise pressure level may rise above 70 dB(A). This can cause hearing damage.

f Always wear hearing protection when you work in the vicinity of a running SYDFE1 control system.

Hot surfaces!Risk of burning.The SYDFE1 control systems heats up considerably during operation. The pilot valve of the SYDFE1 control system gets so hot during operation that you may burn yourself.

f Let the SYDFE1 control system cool down before touching it. f Protect yourself by wearing heat-resistant protective clothing, e.g. gloves.

Risk of intoxication and injury!Contact with hydraulic fluids can be damaging to your health (e.g. eye injuries, skin damage, intoxication upon inhalation and swallowing).

f Always check the lines for wear and damage before each commissioning. f While performing these checks, wear safety gloves, safety goggles and

suitable working clothes. f If hydraulic fluid should, nevertheless, come into contact with your eyes or

penetrate your skin, consult a doctor immediately. f When handling hydraulic fluids, strictly observe the safety notes of the

hydraulic fluid manufacturer.

Risk of fire!Hydraulic fluid is easily inflammable.

f Keep open fire and sources of ignition away from the SYDFE1 control system.

f Ensure sufficient ventilation.

CAUTIOnImproperly installed lines and cables!Risk of stumbling!

f Install cables and lines in a way that nobody can stumble over them.

Uncontrolled system behavior!The failure of individual components can lead to malfunction of the assembly and therefore to unforeseeable behavior!

f Replace or have defective components replaced immediately.


Safety instructions

2.7 Personal protective equipmentPersonal protective equipment for users of the product consists of:

• Protective gloves and safety shoes for transporting the SYDFE1 control system. • Hearing protection for working in the direct vicinity of the running system.

All components of personal protective equipment must be intact.


General notes on damage to material and the product

3 General notes on damage to material and the product

NOTICEImpermissible mechanical loading!Hitting or impulsive forces on the drive shaft or the pilot valve can damage or even destroy the SYDFE1 control system.

f Do not hit the coupling or drive shaft of the axial piston unit. f Do not set/place the axial piston unit on the drive shaft or the pilot valve. f Never use the SYDFE1 control system as a handle or step. Do not place/lay

any objects on it.

Foreign bodies and contaminants in the control system!Risk of damage, wear and malfunction due to the ingress of contaminants and foreign bodies.

f When installing the control system, observe strictest cleanliness to prevent foreign bodes such as welding beads or metal cuttings from entering hydraulic lines.

f Before commissioning, make sure that all hydraulic connections are tight and that all seals and closing elements of plug-in connections are correctly installed and not damaged.

f Take care that no detergents enter the hydraulic system. f Do not use cotton waste or linty cloths for cleaning. f Never use hemp as sealant.

wear!Wear can cause malfunction.

f Carry out the prescribed maintenance work at the time intervals specified in the operating instructions.

Hydraulic fluid is detrimental to the environment!Hydraulic fluid leakage leads to environmental contamination.

f Remove any leakage immediately. f Dispose of the hydraulic fluid according to the national regulations in your

country.

Insufficient pressure! If the pressure falls below the specified value, damage can occur or the product be destroyed.

f Make sure that the pressure cannot fall under the prescribed minimum value.

Insufficient hydraulic fluid!If you commission or operate the SYDFE1 control system without or with insufficient hydraulic fluid, the control system is immediately damaged or even destroyed.

f When commissioning or re-commissioning a machine or system, make certain that the housing chamber as well as the suction and working lines of the control system are filled with hydraulic fluid and remain filled during operation.


Delivery contents

4 Delivery contents

Fig. 1: Control system SYDFE1-3X

The following is included in the scope of delivery:

• 1 control system SYDFE1

Before delivery, the following parts are mounted additionally:1 Transport protection for drive shaft end in the case of keyed shaft2 Protective cover with mounting screws3 Plastic plugs/plug screws4 Protective cover (NG140) or plastic plug on pre-load valve5 The connection flange is closed operationally safe with a cover (optionally on

variant with through-drive)

2

2

5

3

1

5

43


Product description

5 Product description

5.1 Performance descriptionThe SYDFE1 control system is designed and built for the electrohydraulic control of swivel angle, pressure and power (optional) of an axial piston unit. It is intended for stationary applications.Please refer to the data sheet and order confirmation for the technical data, operating conditions and operating limits of the SYDFE1 control system.

5.2 Device descriptionThe SYDFE1 control system is based on an axial piston variable displacement pump of swashplate design for hydrostatic drives in the open circuit. The flow is proportional to drive speed and displacement. The flow can be steplessly changed by adjusting the swashplate.With an open circuit, the hydraulic fluid flows from the tank to the variable displacement pump and is transported from there to the consumer via a directional valve. From the consumer, the hydraulic fluid flows via the directional valve back to the tank.In the regenerative operating mode (see Chapter 5.4.1 „Regenerative operation“ on page 22) the hydraulic fluid can also flow from the consumer through the pump to the tank.

5.2.1 Functional description, section of SYDFE1The numbers in the description below refer to Fig. 2 and Fig. 3 on page 18. Pressure and swivel angle control of the SYDFE1 control systems is accomplished using an electrically controlled proportional valve (2). The proportional valve determines the position of the swashplate (1) by means of the actuating piston (4). The displaced flow is proportional to the position of the swashplate. The counter-piston (3), which is pre-loaded by a spring (5), is permanently pressurized to pump pressure.With a non-rotating pump and depressurized actuating system, the swashplate is held by the spring (5) in position +100 %. With a driven pump and a de-energized proportional solenoid (8) the system swivels to zero stroke pressure as the valve spool (9) is pushed to the initial position by the spring (10) and, therefore, pump pressure p is applied to the actuating piston (4) via valve port “A”. A balance between the pump pressure on the actuating piston and the spring force (5) is achieved at a pressure of 8 to 12 bar. This basic position (= zero stroke operation) is obtained when the control electronics is inactive (e.g. when the controller enable has not been granted).

In contrast to this, a pump with external supply swivels to the negative limit stop (regenerative operation).

The proportional valve is controlled by external control electronics VT 5041-3X, which is part of the system. This electronics processes all of the control signals required to operate the SYDFE1 control system.The external control electronics type VT 5041-3X is designed as plug-in card in Euro-format. As a standard, it is provided with one command value input each for pressure and swivel angle (and optional input for power command value). A pressure transducer senses the actual pressure value. A swivel angle sensor (7) on the pump senses the actual swivel angle value. The acquired actual values are processed in the control electronics and compared with the given command values. A minimum value comparator ensures that automatically only

Open circuit


Product description

the controller assigned to the desired working point is active. In this process, one system variable (pressure, swivel angle or - optionally - power) is exactly corrected, the other two system variables are below the given command value. The output signal of the minimum value generator becomes the command value for the valve control loop.The actual value of the valve spool position is sensed using an inductive position transducer (6). The output value of the valve position controller determines via the amplifier output stage the current through the proportional solenoid (8). As soon as the working point is reached the proportional valve control spool (9) is held in the centered position.When the higher-level controllers demand an increase in the swivel angle (increase in flow), the valve spool (9) must be moved from the central position (connection of the actuating piston (4) A → T) until the swivel angle reaches the required value. The movement of the valve spool against the force of the spring (10) is achieved by a corresponding increase in the electrical current through the proportional solenoid (8).A reduction of the swivel angle (reduction in flow) is achieved by connecting the actuating piston (4) from P → A.

Since the introduction of A10VSO, series 32, a so-called pre-compression volume (14) PCV has been available as an optional extra. This variant (feature “32” in the ordering code for the design of the subplate) is an integral part of the subplate and cannot be retrofitted.The PCV reduces pressure pulsation and can contribute to an improvement in the generation of noise and render secondary measures for the reduction of pulsation unnecessary. This technology is, however, not employed in the subplate variant without PCV (feature “22” in the ordering code).

The actuating system of the pump can be supplied with pilot oil in three different ways:1. Internally, without pre-load valve (only possible for operating pressures above

12...20 bar, see Chapter 4.5.1 “Internal/external pilot oil“ on page 25)2. Internally, with pre-load valve (operating pressure 0…100 %)3. External supply via a shuttle valve - automatic changeover between internal/

external via a shuttle valve sandwich plate (see “external pilot oil” on page 26).

Pre-compression volume PCV

Actuating system supply


Product description

Fig. 2: Type SYDFE1, series 2X

Fig. 3: Type SYDFE1, series 3X

P A T

5 3 7

89102

41

6

1 4–100% Nullhub +100%

5 3 14

P A T

10 9 8

7

6

2

-100 % +100 %Zero stroke

pressure


Product description

The sectional drawings overleaf show the mechanical basic position “+100 %“ of the pump (depressurized, drive at rest). This corresponds to the maximum swivel angle of the pump.Zero stroke pressure: Pressure, which the pump with internal supply generates for its own supply without activation of the pilot valve. The pressure level is usually within the range of 8 to 12 bar. This pressure level can only be achieved when the maximum oil flow, which the pump can deliver, is not exceeded. The pump with internal supply automatically swivels in to zero stroke operation after the electric drive was started and

• when the enable of the control electronics is missing or • in the case of an error message of the control electronics (pre-condition:

VT 5041-3X: J1 OFF) or • when the control electronics is de-energized

provided that the required pilot pressure can be built up (consumer line is closed).In contrast to this, the pump with external supply swivels in to the negative limit stop “-100%“ under the above conditions!

nOTICE! Cavitation of the pump!Risk of damage to the pump in the case of systems with external supply.

f To prevent damage to the pump, provide a pressure relief/anti-cavitation valve for systems with external supply. If a fault occurs during operation - not during start-up - the motor must be switched off.

5.3 Controller structure and basic operating modes The controller structure is illustrated in the figure below.

Fig. 4: Controller structure

Up to three controllers are continuously active in the possible operating modes:

• Swivel angle controller • Pressure controller • Power controller (optional)

These controllers alternate automatically and jerk-free through evaluation of minimum value comparators. During steady-state operation, one of the above controllers is active. For the other controllers, the actual value is smaller than the command value.The following operating modes are available:

Basic positions of the swivel angle adjustment feature

Controller structure

SYD_006

sU

Up

sU

Power controller (option)

(Pin 24c) Actual pressure (pin 8c/10c)

Pressure controller

Minimum value

comparator

Flow controller

Minimum value

comparator

Valve controller

Valve command value

Power setpoint (potentiometer or pin 18c/20c)

Swivel angle setpoint (pin 14c/16c)

Actual swivel angle (pin 12c)

Pressure setpoint (pin 6c/4c)

Basic operating modes


Product description

5.3.1 Closed-loop swivel angle controlwith version VT 5041-3X/1... VT 5041-3X/2...

f J4 OFF and f connect pin 18a to +24 V.

with version VT 5041-3X/3...If the axis is to run exclusively in this operating mode, an analog signal within the range of +10.0 V to UB is assigned to the pressure command value and used to deactivate the pressure controller (0...+10 V ≙ 0...100 % swivel angle).

The pressure transducer signal must be short-circuited or deactivated, because even actual pressure value signals of ≥ 8.0 V have an influence on or reduce the swivel angle output and hence the valve command value (actuating speed!).

A precondition for this is, however, that the electronics is set for an actual pressure value input “voltage” without raised zero point (e.g. 0 - 10 V, 0 - 20 mA). Otherwise, electronics set for an actual pressure value branch with raised zero point would change to an erroneous state when the pressure transducer signal is missing.

uu

uu

uu

SYD_008

+10 V to UB external

H

L

6c

4c

8c

10c

14c

16c

pcomm

Reference potential

pact →0 to +10 V

0 to 5 V

SWAcomm → -10 V to +10 V

Reference potential

Fig. 5: Circuitry of control electronics VT 5041-3X for closed-loop swivel angle control


Product description

5.3.2 Closed-loop pressure control

wARnInGForcefully ejected parts and hydraulic fluid jet! Risk of severe injury! The electrical pressure control does not assume a pressure relief function.

f Make certain that the maximum operating pressure is never exceeded. f If a pre-load valve is installed, you can use its pressure relief function. If

no pre-load valve is installed, provide a pressure relief valve, the pressure setting of which is 10 % (recommended) higher than the operating pressure, in the pressure line. If you do without this valve, malfunction is possible.

If the axis is to operate in this mode, an analog signal within the range from +10.0 V to UB can be assigned to the swivel angle command value and used to deactivate the swivel angle controller. However, for some applications, it is advantageous to limit the permitted swiveling range of the pump by feedforwarding a suitable swivel angle command value. However, this command value must be sufficiently great in order that the pressure controller can swivel the pump out to the required extent.

5.3.3 Power limitation (optional) with VT 5041-3X/3...This version allows optimum matching with the performance limits of the drive motor.Due to the relationship of P ≈ αcomm * pact the power controller intervenes with a reducing/limiting effect (power hyperbola) via the swivel angle command value branch, if required.

0

100

0 100

Power

Actual pressure [%]

Max

. flo

w [%

]

Fig. 6: Power limitation

5.4 Special operating modesThis chapter describes certain applications. In these cases, the basic operating modes (see Chapter 5.3 on page 19) are active.

For starting up SYDFE1 systems, no hydraulic circuit needs to be provided for the classical start-up at zero pressure.

Starting up at zero pressure


Product description

When small command values for pressure and swivel angle are provided, starting up under almost no-load conditions is possible.

In the case of systems with internal supply and without pre-load valve, hydraulic circulation circuits must be dimensioned so that a minimum pressure of 8...12 bar is obtained, because the pump requires this pressure level to be able to respond to electrical control signals.

Operating mode of the pump, in which an operating point is steadily closed-loop-controlled with a corresponding command value over a longer period of time.Observe the notes on permitted pressures in Chapter 5.5.1 „Internal/external pilot oil“ (page 25).

Operating mode of the pump that refers to the smallest achievable swivel angle and to which the pump usually changes over when no closed-loop control is active.A withdrawal of the enable signal, the non-availability of supply voltage or an error message (exception: J1 set, see page 63) cause the pump to automatically swivel in to zero stroke operation (actuating system with internal supply). Whereas in the case of actuating systems with external supply the pump swivels to the mechanical positive stop “-100%“ (consumer line closed) irrespective of the command value received. The feedforward of “0 bar” via the pressure command value branch is not permitted for actuating systems with external supply. In the case of systems with internal supply this is problematic only in the case of a step-change from a high pressure to 0, because undershoots may occur.

5.4.1 Regenerative operationRegenerative operation is a special operating mode of the SYDFE1 control system, since in this case the SYDFE1 control system is operated as both, generator and motor.We can distinguish between continuous regenerative operation and brief regenerative operation. In the first case, by this we understand coupling of the variable displacement pump with a fixed displacement pump. Here, the two pump displacements are fed together to a common consumer.This operating mode can be utilized in conjunction with a fixed displacement pump in order to increase the displacement. To achieve “zero” displacement, the closed-loop controlled pump must “take over” the entire flow from the fixed displacement pump and therefore swivels to the negative swivel angle range (motor operation). It must be noted here that both pump sizes must be matched to each other so that the controlled pump (in regenerative operation) must swivel in to max. –70 %. The fixed displacement pump should be mounted to a through-drive of the SYDFE1 control system.The following pump variants are available for continuous regenerative operation:0487: Continuous regenerative operation with external supply0541: Continuous regenerative operation without external supply (for SYDFE1-3X only)

In the case of pump variants with external supply this operating mode is somewhat complicated in terms of engineering and commissioning, because a pump swiveling in too far (e.g. -75 % instead of -70 %) causes cavitation. We therefore recommend master/slave operation as an alternative with two closed-loop controlled SYDFE1 systems or pump variant 0541 for SYDFE1-3X.

Circulation operation (by-pass filtration, cooling)

Stand-by operation

Zero stroke operation

Continuous regenerative operation


Product description

Continuous operation is possible when the given operating limits are adhered to. However, at a total displacement of “zero” (that is, at a negative swivel angle of the SYDFE1 pump) and at high pressures, the noise level increases and efficiency deteriorates. For pumps with external supply, the use of a pressure relief and anti-cavitation feature as shown in Fig. 7 is indispensable to prevent the pump’s running dry.

SYD_023

Q1 Q2 max< 0,7 Q1

0,2 barpmax

Pressure relief/anti- cavitation valve required in the case of external supply

Fig. 7: Circuit diagram for continuous regenerative operation

50

100

150

200

280

p[bar]

+10 +20 +30 +40 +50 +60 +70 +80 +90 +100-10-20-30-40-50-60-70-80-90-1000

Ist [%]

p[bar]p[bar]p[bar]

250

SYD_014

Motor operation Pump operation

Control system for continuous regenerative operation:SYDFE1 2X or 3X• NG 18...100 with SO 0487 or 0541• NG 140

Ope

ratin

g pr

essu

re p

HP

(bar

)

Fig. 8: Operating limits for series SYDFE1-2X and SYDFE1-3X with special rotary group for continuous regenerative operation

During brief regenerative operation the variable displacement pump changes over to motor operation for a limited period of time, e.g. for lowering a load. If the requirement profile remains within the limits according to Fig. 9, the standard version of the pump can be used (standard rotary group 0000 or 0479).

Brief regenerative operation


Product description

50

100

150

200

280

p[bar]

+10 +20 +30 +40 +50 +60 +70 +80 +90 +100-10-20-30-40-50-60-70-80-90-1000

Ist [%]

p[bar]p[bar]

250

SYD_028

Motor operation Motor operation

Standard rotary group

Ope

ratin

g pr

essu

re p

HP

(bar

)

Fig. 9: Operating limits for series SYDFE1-2X and SYDFE1-3X with standard rotary group for brief regenerative operation

For standard applications, the command value for the swivel angle is provided within the voltage range of 0…+10 V; this command value is interpreted by the control electronics so that the swivel angle of the pump is controlled within the swiveling range from 0 % displacement to 100 % displacement.During regenerative operation, depending on the pump combination, a swivel angle command value of up to -70 % (or -7 V) has to be provided. If the higher-level control is not able to generate the command value range of -7 V to +10 V, the normalization of the command value provision can be re-configured using jumpers J3 and J5.

Table 6: normalization of swivel angle command value provision

Regenerative operation

JumperJ3 J5

ON ON OFFOFF ON

• Standard: J3 open; J5 set Swivel angle command value -10...+10 V ≙ -100…+100 % swivel angle

• Regenerative operation: J3: set; J5 open Swivel angle command value 0...+10 V ≙ -100 %…+100 % swivel angle or +5 V corresponds to a swivel angle of 0 %.

Example: A swivel angle of -70 % means “zero” displacement of the pump combination. In the “regenerative” mode, this corresponds to a command value provision of +1.5 V for the swivel angle.To vary the displacement for the pump combination from 0 % to 100 %, swivel angle command values between +1.5 V and +10 V must be provided.

OFF


Product description

5.5 Operating pressure limits

wARnInGExcessive pressure! Risk of severe injury!

f Make certain that the maximum operating pressure is not exceeded.

At a pressure of ≥ 250 bar the following restrictions must be observed for SYDFE1:

• The pressure transducer must be located downstream of a pulsation damper or the high-pressure hose.

• When a standard pilot valve spool is used (version “A”), the pressure controller P-gain (see page 70) may have to be reduced. This has an influence on the accuracy and dynamics of the closed pressure control loop.

• The loop gain can also be reduced by installing a pressure transducer of a higher pressure rating (e.g. 400 bar).

The minimum operating pressure depends on the pilot oil supply and is explained in more detail in the following chapter.

5.5.1 Internal/external pilot oilIf the operating pressures of the application are always > 20 bar, the version with internal pilot oil supply should be selected, because no cavitation due to too small command values can occur with this version.Operation is also possible at pressures higher than approximately 12 bar, but dynamics is restricted within the range below 20 bar. This minimum (pilot) pressure level ensures that the pump can respond to the electrical swivel signal at any time. When the consumer line is blocked, the smallest achievable steady-state swivel angle is the zero stroke angle.For applications, in which smaller operating pressures occur or are to be controlled, a pre-load valve (SYDZ for SYDFE1) can be used. In these cases, the minimum pressure is ≥ 1 bar.

The advantage of the pre-load valve is that the pilot oil pressure of the pump cannot fall below the value preset on the pre-load valve and that pressures ≤10 bar on the output side can be continuously controlled. Being equipped with a pre-load valve the pump cannot permanently swivel back over zero, irrespective of electrical actuating signals or any control errors. This is not valid for applications, in which, for example, a suspended load can cause operating pressures ≥ 12 bar. In such cases the pump can also be used in motor operation (for lowering the load). A check valve integrated in the pre-load valve permits, within certain limits, a reversal of the direction of oil flow.

When using the pump combinations

• NG45 with 45/28/18 or • NG28 with 28/18 or • NG18 with 18

in conjunction with the SYDZ pre-load valve on the main pump, there is a mechanical conflict between port “P1” of the pre-load valve and the swivel angle sensor housing of the built-on rear pump. For this reason, we suggest that the main pump of the above combinations be equipped with an SAE flange plate ¾“ (NG28) or 1“ (NG45) having a height of h = 45 mm. The

Maximum operating pressure

Minimum operating pressure

Internal pilot oil supply

Pre-load valve


Product description

construction height of the pump assembly therefore changes by dimension “h“.

Also here, the minimum pressure is ≥ 1 bar. With external pilot oil supply (0479 for external supply or 0487 for external supply plus regenerative operation for SYDFE1) pressures ≤ 10 bar are only permitted briefly (max. 10 minutes).An additionally built-on sandwich plate with shuttle valve automatically switches the pilot oil supply between internal or external pilot oil source, with always the higher pressure level being selected.A pump for SYDFE1 with external pilot oil supply can be recognized by

• the sandwich plate mounted under the pilot valve and • the hose routed around the pump case.

With external pilot oil supply, the actuating system of the SYDFE1 pump works independently of the actual high-pressure circuit, thus allowing an adjustment also below an operating pressure of 14 bar within the range of “±100 %“ (change in the direction of displacement!).

In the following situations, the pump swivels to position “-100 %” (motor operation) in an uncontrolled manner:

• When the enable of the control electronics is missing or • in the case of an error message (exception: J1 set, see page 63) or • in the de-energized state of the control electronics.

This can lead to cavitation and damage to the pump.

For this reason, special features are to be provided such as a pressure relief and anti-cavitation valve and actual swivel angle value monitoring.The pressure relief and anti-cavitation valve diminishes the risk of the pump’s running dry, the effects of which result in a reduction in the pump’s service life.The actual swivel angle value monitor could, for example, switch off the entire drive or selectively shut off the pilot oil flow.The following is valid for the actuating pressure:

Pilot oil pressure ≤ minimum operating pressure + 30 barRecommendation: Absolute pilot oil pressure ≈ 20 barFurther notes on the operation with external supply:

• With external supply, the pump does not swivel to zero stroke when the control electronics is de-energized.

• Command values for pressure and flow must always be greater than 1 bar or 5 %, because there is no exact “zero” pressure or “zero” swivel angle due to drift or inaccurate settings. For this reason, selections equal to zero or slightly greater can lead to cavitation in the worst case.

• In order to ensure sufficient lubrication for the pump system at all times, the actual pressure value must not be less than 10 bar for longer than 10 minutes!!

At a pilot oil pressure of 20 bar the brief pilot oil requirement during swiveling is ca.17 l/min. In practice, this amount of pilot oil is needed only, if the operating pressure is less than 20 bar during the entire swiveling process and thus the entire pilot oil demand must be supplied by the external source.In the steady-state, balanced condition, the pilot oil requirement is less than 1 l/min.Experience has shown that, depending on the operating pressure and swiveling frequency, the actual pilot oil demand is in the order of 5...15 l/min. In the case of external supply, a smaller pump size may be selected if an accumulator is provided.

External pilot oil supply

notes on dimensioning


Product description

5.6 Ambient conditions

5.6.1 Oil-immersed applications

The SYDFE1 control system is suitable for oil-immersed applications.

5.6.2 Ambient temperatureThe permissible maximum ambient temperature for SYDFE1 control systems is 70 °C at the pump and 50 °C at control electronics VT 5041-3X.

We recommend the installation within a ventilated area with moved ambient air, e.g. in the air flow of an electric motor.

5.7 notes on the selection of hydraulic fluidsGeneral

The SYDFE1 control system is designed for operation with hydraulic fluids in accordance with DIN 51 524 (HL/HLP).We recommend that the operating viscosity (at operating temperature) be within the following range, which is optimum in terms of efficiency and service life:

• νopt = optimum operating viscosity 16... 36 mm²/s

This range is referred to the tank temperature in the open circuit.

The following values are valid for limiting operating conditions:

• νmin = 10 mm²/s Briefly, at max. permissible case drain oil temperature of 90 °C

• νmax = 1000 mm²/s Briefly, during cold start

The temperature of the hydraulic fluids lies between the following values: (cf. selection diagram)

• tmin = -20 °C • tmax = 70 °C

Operating viscosity

Viscosity limits

Temperature range


Product description

tmin = -20 °Ct in °C

tmax = +70 °C

5

10

4060

20

100

200

400600

100016002500 0° 20° 40° 60° 80° 100°-40° -20°

νopt.16

36

5

1600

-40° -25° -10° 10° 30° 50° 90°70°0°

VG 22VG 32VG 46VG 68VG 100

Temperature

Hydraulic fluid temperature range

Visc

osity

Notes on the selection In order to be able to select the correct hydraulic fluid, the operating temperature in the tank (open circuit) in relation to the ambient temperature must be known.

The hydraulic fluid should be selected so that within the operating temperature range, the operating viscosity is within the optimal range (νopt). This range is shown as shaded area in the selection diagram. We recommend that you select the next higher viscosity class.Example: At an ambient temperature of X °C, the resulting temperature in the tank is 60 °C. Within the optimum operating viscosity range (νopt; grey-shaded area) this corresponds to viscosity classes VG 46 and VG 68. You should select: VG 68.

The case drain oil temperature, which is subject to the influence of pressure and pump revving speed, is always higher than the tank temperature. However, the temperature must not exceed 90 °C at any point in the system. If the conditions described above cannot be complied with due to extreme operating parameters or high ambient temperatures, please consult us.

The finer the filtration of the hydraulic fluid, the better is the achieved cleanliness class, which, in turn, prolongs the service life of the SYDFE1 control system.To ensure operational reliability of the SYDFE1 control system, at least cleanliness class 18/16/13 according to ISO 4406 (for particle sizes 4/6/14 μm) is required.

5.8 noise levelWhen compared with, for example, vane pumps, axial piston pumps generate greater changes in flows and thus pressure pulsations for design-inherent reasons. Apart from the propagation of air and structure-borne noise, this can have an influence on fluid-borne noise. In the end, these factors together result in the general perception of “noise”.Noise often induces vibration on other components, which, in turn, also generate noise. For example, on check valves, which may be installed, the integrated springs must be adapted to the conditions of the systems, if this is a cause of excitations leading to the generation of noise.

Selection diagram for the hydraulic fluid

Filtration of the hydraulic fluid


Product description

The details given for the noise pressure level in the technical documentation refer to measurements taken in an anechoic room. Influences of the surroundings such as place of installation, general mechanical concept, piping, etc., are not taken into account.

5.8.1 Generation of noise in the power unit“Noise“ is composed of different elements. The total result of “noise” is influenced not only by air-borne noise, but also by structure- and fluid-borne noise. As a result of unfavorable installation and piping conditions, the noise pressure level of the complete system can be 5 to 10 dB(A) higher than the value of the pump alone. Noise can be reduced by taking, for example, the following measures:

• Low-noise tank • Damping ring between pump and pump mounting bracket • Flexible pipe conduit • Anti-vibration rails under the motor • Installation of the pump at a sufficient distance to the tank wall

5.8.2 Pulsation damperFor some special applications, we recommend the use of a pulsation damper. Due to the reduction of typical pump pressure pulsation, this has a positive effect on the noise level of the hydraulic system as a whole. Further information can be found in data sheet RE 50142.

5.9 Shaft variantsThe SYDFE1 control system is available with keyed or splined shafts. When compared with the keyed shaft, the splined shaft is not only advantageous with regard to its degrees of freedom during assembly and operation, but also due to its increased torque load carrying capacity and its stability under changing loads. This increased torque load carrying capacity is useful in particular when pump combinations are to be installed. In the case of multiple pumps, all built-on units are fitted with splined shafts.In view of the dynamic load carrying capacity and standardization, we recommend the use of standard types with splined shafts. This offers advantages with regard to availability and future spare parts requirements. When a splined shaft is selected, a clamp coupling must be used for the mechanical connection to the electric motor. Otherwise, frictional corrosion may occur that leads to damage to the pump.Notes on the transmission of permissible maximum torques can be found in the data sheet.


Product description

Keyed shaftDue to the advantages of the splined shaft, keyed shafts are not recommended for new applications. The keyed shaft is no longer used for applications with through-drive.If a single pump is to be used later as “end pump” in a multiple-pump system, a splined shaft must be selected.

Splined shaftSplined shaft profiles depend on the size (NG) of the pump. Two different splined shaft profiles are available in conjunction with “SYDFEx“ :

• “S“-profile for NG18, NG100 and NG140 • “R“-profile for NG28 ... 71

When compared with the “S”-profile, the “R”-profile features further improved properties with regard to the torque carrying capacity of the shaft. This version represents the optimum for a wide variety of applications.

5.10 Spool variant of the VT-DFPE-x-2X pilot valveThe standard spool according to the ordering code is spool type “A“ (360° spool). Especially for press applications (280 bar) type “C” (4-groove spool) has proven in practice in conjunction with the SYDFE1 control system.On older systems, a 2-groove spool “B” was often employed. However, this spool should no longer be used for new applications due its poor dynamics.

5.11 Functions of control electronics VT 5041-3X

5.11.1 Enable

wARnInGUncontrolled machine movements! Risk of severe injury! The enable does not represent a safety function!

f All further, safety-relevant interventions must be made by the higher-level control (e.g. switching the drive motor OFF, closing the shut-off valves, .... ).

The enable for the control electronics is granted by applying 24 V to switching input 26c. This activates the output stage of the VT 5041-3X, i.e. the pilot valve. The presence of the enable is signaled by LED “En.“ on the front panel.The following options are provided for connecting enable input 26c:

• Controlling by higher-level control (to be preferred) • Fixed wire bridge • Via relay • Conventional switch

The withdrawal of the enable signal at 26c deactivates the valve output stage of the control electronics and causes the pilot valve to go to a defined position. The same effect is achieved by switching off the voltage supply.


Product description

This has the following consequences:

• With an actuating system with internal supply the pump swivels to the zero stroke position. Zero stroke = minimum pressure generated by a pump with internal supply

• In contrast to this, a pump with actuating system with external supply swivels to the mechanical limit stop “-100 %“.

The enable is always required for normal operation. In the event of a fault, such a fault can be cleared by withdrawing and re-applying the enable. Clearing of the fault message is also possible by switching the supply voltage off and then on again.

5.11.2 Switch TD Via switching input “Switch Td“ (22c) you can activate a second volume adjustment.This function is a new feature when compared with control electronics VT 5041-2X and is explained in more detail in Chapter 8 “Commissioning“ on page 59.

5.11.3 Pressure controller

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