Test device for control system SY(H)DFEE

Operating instructionsRE 29689-B/11.2019

Replaces: 01.2003English

Test device for control system SY(H)DFEE

Type VT-PDFE-1X...

The data specified only serve to describe the product. If information on the use of the product is given, it is only to be regarded as application examples and recommendations. Catalog information does not constitute warranted properties. The information given does not release the user from the obligation of own judgment and verification. 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 AG. It may not be reproduced or given to third parties without its consent.

The cover shows an example configuration. The product supplied may differ from the solution shown here.

The original operating instructions were prepared in German.

RE 29689-B/11.2019; VT-PDFE-1X..., Bosch Rexroth AG

3/32 Content

Content

1 About this documentation 51.1 Validity of the documentation 51.2 Required and supplementary documentation 51.3 Representation of information 52 Safety instructions 72.1 About this chapter 72.2 Intended use 72.3 Improper use 72.4 Qualification of personnel 72.5 General safety instructions 82.6 Product-specific safety instructions 92.7 Safety equipment 122.8 Personal protective equipment 123 General information on damage to property and damage to the product 134 Scope of delivery 145 About this product 145.1 Performance description 145.2 Product description 155.3 Identification of the product 206 Transport and storage 207 Installation 217.1 Unpacking 217.2 Installation conditions 217.3 Required tools 217.4 Before use 217.5 Place of use 217.6 Installing the test device for SY(H)DFEE systems 228 Commissioning 248.1 Initial commissioning 249 Operation 2410 Maintenance and repair 2410.1 Cleaning and care 2510.2 Repair 2510.3 Spare parts 2511 Demounting and replacement 2611.1 Required tools 2611.2 Preparing demounting 2611.3 Preparations for storage and further use 2612 Disposal 2612.1 Environmental protection 2612.2 Return to Bosch Rexroth AG 2712.3 Packaging 2712.4 Materials used 2712.5 Recycling 2713 Extension and modification 2714 Troubleshooting 28

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Bosch Rexroth AG, VT-PDFE-1X...; RE 29689-B/11.2019

14.1 How to proceed for troubleshooting 2815 Technical data 2816 Annex 2916.1 List of addresses 2917 Alphabetical index 30

About this documentation 5/32


1 About this documentation

1.1 Validity of the documentationThis documentation is valid for the test device VT-PDFE-1-1X/V0/0, Mat. no. R900757051.

This documentation is intended for fitters, operators, service technicians and plant operators.This documentation contains important information on the safe and appropriate installation, transport, commissioning, operation, use, maintenance, and removal of the product.

▶ Read this documentation thoroughly and in particular chapter 2 “Safety instructions“ and chapter 3 “General information on damage to property and damage to the product“, before working with the product.

1.2 Required and supplementary documentation ▶ Only commission the product, when you have the data sheet marked with

the book symbol at hand and when you have read and understood the documentation of the valve that you wish to test or commission.

Bosch Rexroth data sheets and operating instructions are available online at www.boschrexroth.com by entering the type code in the search function.

Table 1: Required and supplementary documentation

1.3 Representation of informationIn order to allow you to work directly and safely with the test device described, standardized safety notes, symbols, terms and abbreviations are used in this documentation. For a better understanding, they are explained in the following sections.

1.3.1 Safety instructionsIn this documentation, safety instructions are included in chapter 2.6 “Product-specific safety instructions“ and in chapter 3 “General information on damage to property and damage to the product“ and whenever sequences of actions or instructions are explained which bear the risk of personal injury or damage to property. The described hazard avoidance measures must always be observed.

Title Document number Document type

Proportional directional valves, direct operated, with electrical position feedback as pilot control valve for control systems SY(H)DFE., Type VT-DFP.

29016 Data sheet

Pressure and flow control system, SYDFEE series 2X, 3X, SYHDFEE series 1X 30012-B Operating instructions

Variable-speed pressure and flow control system Sytronix DFEn 5000, Type SYHDFEn, type SYDFEn

20014-B Operating instructions

SYDFED series 2X, 3X, SYHDFED series 1X, Pressure and flow control system 30017-B Operating instructions

6/32 About this documentation


Safety instructions are structured as follows:

SIGNAL WORDType and source of danger!Consequences in case of non-compliance

▶ Hazard avoidance measures ▶ <Enumeration>

• Warning symbol: draws attention to a hazard • Signal word: identifies the degree of hazard • Type and source of danger: Specifies the type and source of danger • Consequences: describes the consequences in case of non-observance • Precaution: specifies how the hazardous situation can be prevented

Table 2: Hazard Classifications according to ANSI Z535.6-2011

Warning sign, signal word Meaning

DANGERIndicates a hazardous situation which, if not avoided, will certainly result in death or serious injury.

WARNINGIndicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONIndicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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

1.3.2 SymbolsThe following symbols indicate notices which are not safety-relevant but increase the comprehensibility of the documentation.

Table 3: Meaning of the symbols

Symbol Meaning

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

▶ Individual, independent action

1. 2. 3.

Numbered instruction:The numbers indicate that the actions must be carried out one after the other.

1.3.3 DesignationsThe following terms are used in this documentation:

Table 4: Designations

Designation Meaning

DFE system Pump control system with integrated electronics

Test device Device included in the scope of delivery for testing SY(H)DFEE control systems

RE xxxxx Rexroth document in English language

Safety instructions 7/32


2 Safety instructions

2.1 About this chapterThe test device described in the following has been manufactured according to good engineering practice. However, there is still a risk of personal injury and/or damage to property if you do not observe this chapter and the safety instructions in this documentation.

▶ Read this documentation completely and thoroughly before working with the product.

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

▶ Always include the required documentation when you pass the service case with the test device on to third parties.

2.2 Intended useThe test device is suitable for activating and functional testing of Bosch Rexroth SY(H)DFEx systems with integrated electronics and 11+PE connection.The technical data of the device have to be observed without exception, and the specified ambient conditions have to be adhered to, see chapter 15 “Technical data“ on page 28.The use in potentially explosive atmospheres is not permitted.The device is provided for temporary use in a controlled electromagnetic environment (according to EN 61326-1, table 3, testing according to EN 61326-2-1) on hydraulic industrial equipment for commissioning, analyzing, testing and servicing of hydraulic valves in plant.Dry and clean ambient conditions have to be ensured.

2.3 Improper useAny use other than described in the section “Intended use” is considered as improper and is therefore not permitted und renders any warranty claims null and void. It is also regarded as improper use if the test device is operated outside the indicated performance limits and operating conditions, especially the prescribed ambient conditions.The test device is not provided for use in Class B environments (domestic/residential). Should the test device nevertheless be used in a domestic/residential, controlled electromagnetic environment (emission limit values of class B), further measures have to be taken to prevent electromagnetic interference.Bosch Rexroth AG does not assume any liability for damage caused by improper use. The user assumes all risks involved with improper use.

2.4 Qualification of personnelThe activities described in this documentation require basic knowledge of electrical installation, control technology, programming and hydraulics as well as knowledge of the appropriate technical terms. In order to ensure safe use, these activities may only be carried out by an expert in the respective field or an instructed person under the direction and supervision of an expert.

8/32 Safety instructions


Experts are those who are able to recognize potential hazards and apply the appropriate safety measures due to their professional training, knowledge and experience, as well as their understanding of the relevant requirements pertaining to the work to be undertaken. An expert must observe the relevant specific professional rules and have the necessary hydraulic expert knowledge.Expert knowledge means, amongst others: • the ability to read and completely understand circuit diagrams, • in particular, completely understanding the correlations regarding safety equipment and

• knowledge of the function and structure of hydraulic components, • knowledge of the function and structure of electrical systems and components.

When working with the test device on a system/machine, it is advantageous if the work is carried out by a specialist who is familiar with the system!

It is assumed that the device is used by trained and professional personnel in a controlled electromagnetic environment to ensure proper usage.

Bosch Rexroth offers training courses that support your qualification in specific fields. You can find an overview of training contents on the Internet at: https://www.boschrexroth.com

2.5 General safety instructions • Observe the valid regulations on accident prevention and environmental protection.

• Observe the safety regulations and provisions of the country in which the product is used/applied.

• Exclusively use Rexroth products in technically perfect condition. • Observe all notices 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 genuine Rexroth accessories and spare parts in order to exclude any hazard to persons due to unsuitable spare parts.

• Comply with the technical data and ambient conditions specified in the product documentation.

• The installation or use of inappropriate products in safety-relevant applications could result in unintended operating states in the application which in turn could cause personal injuries and/or damage to property.

• Do not commission the product until you can be sure that the end product (for example a machine/system) where the Rexroth products are installed comply with the country-specific provisions, safety regulations and standards of the application.

• Please observe the safety-relevant information and risk specifications in the operating instructions of the manufacturer of the connected hydraulic system before commissioning the control with a hydraulic system.



• Please observe the general installation and safety regulations when working on electrical systems.

• The information given in the product documentation with regard to the use of the supplied components represents only application examples and recommendations. The user has to check the suitability of the supplied device and the information given in this documentation with regard to its use self-dependently for his individual application as well as the compliance with the safety regulations and standards valid for his application, and carry out the required measures, changes and amendments.

• Technical data as well as connection and installation conditions are available in the product documentation and have to be imperatively observed.

• In case of faults impairing the safety and changes in the operating behavior, shut down the test device immediately and report the faults to the responsible personnel.

• Generally, you must not modify or convert the product.

2.6 Product-specific safety instructions

WARNINGNo functional safety!Electronic pump systems provide machines or systems with hydraulic pressure. In the case of mechanical and electrical faults, e.g. failure of the power supply, persons may get caught, hurled or crushed by the installation.

▶ When using the test device in a system/machine make sure that it will not make the functional safety of the system/machine ineffective or affect it in whatever way!

Non-observance of control signals on the system side!If control-side safety precautions are provided, they will be rendered ineffective.

▶ The test device may be used exclusively by personnel who are familiar with the device, the valve and the hydraulic system. No liability is accepted for damage caused by operating errors.



WARNINGHazardous movements!It is not allowed for persons to stay within the range of motion of the machines, in which the test device is to be used. The following are examples of possible measures against unintended access of persons: • Protective fences • Protective grids • Protective covers • Warning signs, barrier tapes ▶ If persons have to enter the hazard zone while the control is active, provide

superordinate monitoring functions on the system side or measures for personal safety. These measures must be provided according to the specific data of the system and on the basis of the risk and error analysis of the system manufacturer/user. In this connection, the safety provisions applied for the system must be taken into account.

▶ In case of faults impairing the safety and changes in the operating behavior, shut down the test device and the valve immediately and report the faults to the responsible personnel.

System parts under pressure and ejecting hydraulic fluid!When working on hydraulic systems with stored pressure energy (accumulator or cylinders working under gravity), valves may even be pressurized after the pressure supply has been switched off. During installation and demounting, the valves or parts may be hurled around and cause personal injuries and/or damage to property. There is moreover the risk of serious injury caused by a powerful, ejecting hydraulic fluid jet.

▶ Before installing the test device in the hydraulic system, ensure that the hydraulic system is depressurized and the electrical control de-energized.

▶ Completely depressurize machines and systems before working on hydraulic products.

Improper mounting or placement!The test device is a mobile device, which is not provided for firm installation in the system/machine. While being used, the device is connected to the measuring line and is placed loosely in/on the system.

▶ Place the device so that it cannot fall down. ▶ Place the device so that no one can step on it. ▶ Make sure that the measuring line does not pose a risk of stumbling for third

parties or the operator himself/herself.



WARNINGHigh electrical voltage by incorrect connection!Danger to life, risk of injury by electric shock!

▶ The test device may only be connected by or under the supervision of a specialized electrician.

▶ Switch off the power supply before any work, during which the test device is installed in the system, and secure it against restarting.

▶ Provide for proper, safe PE connection. ▶ Provide the supply voltage according to VDE0100 part 410. ▶ Only connect voltages and power circuits that feature safe isolation from

dangerous voltages. Safe isolation can be achieved with isolation transformers, safe optocouplers or mains-free battery operation, for example.

▶ Use exclusively the existing cables and leads for interconnecting the test device in the valve control cable.

Missing equipotential bonding!Electrostatic processes, an incorrect earthing concept or missing equipotential bonding may lead to malfunctions or uncontrolled movements at the machine and thus cause injuries.

▶ Provide for correct earthing and provide for proper equipotential bonding when you connect the device in the machine.

Penetrating water and humidity!In case of use in humid or wet environments, water or humidity may penetrate at electrical plug-in connectors or the valve electronics. This case may lead to malfunctions at the test device and to unexpected movements in the hydraulic system which may result in personal injury and damage to property.

▶ Only use the test device within the intended IP protection class or lower. ▶ Ensure before the installation that all seals and caps of the plug-in

connections are present and intact.

CAUTIONExceedance of the maximum temperatures!Use of the test device outside the intended temperatures may lead to functional failures. In the worst case, this may result in unexpected system movements and thus constitute a risk of injury.

▶ Only use the test device within the ambient temperatures provided for it.



CAUTIONCorrosion!If the test device is used in humid environments or water, the test device and the sockets may corrode. Mounting screws and measuring sockets may lose their function or their stability, respectively. This may lead to malfunction and cause a risk of injury.

▶ Do not use the test device with corroded measuring sockets.

Generally, avoid contact with salt water and salt-laden atmospheres!

2.7 Safety equipment

WARNINGHazardous movements!Danger to life, risk of injury or damage to property!

▶ Only the systems/valves listed in these operating instructions may be operated with this test device.

2.8 Personal protective equipmentCheck determined personal protective equipment for completeness and protective effect and wear it (observe customer regulations and list of personal protective equipment).

General information on damage to property and damage to the product 13/32


3 General information on damage to property and damage to the product

NOTICEImpermissible mechanical loading!Impact or shock forces on the test device may damage or even destroy it.

▶ Do not place/put any objects on top of it. ▶ Place the test device at locations, where it cannot fall down.

Malfunction and deformations!Hydraulic components may reach high temperatures during operation. If the test device heats up excessively when in contact with hot surfaces, malfunctions may occur and the plastic housing of the test device may deform.

▶ Do not place the test device on or directly next to hot surfaces or places in or on the system.

Dirt and foreign particles in hydraulic components!Penetrating dirt and foreign particles lead to wear and malfunctions. Reliable operation is thus no longer ensured.

▶ During installation, ensure utmost cleanliness in order to prevent foreign particles such as welding beads or metal chips from getting into the hydraulic lines.

▶ Do not use linty cloth for cleaning. ▶ Take care that no cleaning agents enter the housing.

Environmentally harmful electronic components!Various integral components can lead to environmental pollution.

▶ Dispose of defective components in accordance with the currently applicable national provisions in your country.

Uncontrolled disconnection and connection of plug-in connectors!Device might be destroyed!

▶ Before carrying out any installation work, disconnect the device from the mains or from the voltage source or de-energize it reliably.

▶ Do not plug in or pull electrical plug-in connectors as long as the voltage supply is activated.

The warranty only applies to the delivered configuration.The warranty becomes void if the product is incorrectly mounted, commissioned or operated, not used as intended and/or handled improperly.

14/32 Scope of delivery


4 Scope of deliveryThe scope of delivery includes: • Test device type VT-PDFE-1-1X/V0/0, Mat no. R900757051

▶ Check the scope of delivery for possible transport damage, see chapter 6 “Transport and storage”.

In case of complaints, please contact Bosch Rexroth AG, see chapter 16.1 “List of addresses”.

5 About this product

5.1 Performance descriptionThe test device is designed primarily for use with the control system SY(H)DFEE. It may, in addition, be used for all SY(H)DFEx systems with 11+PE connector - possibly with a restricted scope of functions. The device an be plugged like an extension cable into the incoming cable of the proportional valve VT-DFPx. All signals from and to the pilot valve can be measured and evaluated at the measuring sockets (2 mm). This allows quick diagnostics in the case of problems in conjunction with the pump system.Generally, the following applications are conceivable: • The device is used as intermediate adapter and serves exclusively to make signals measurable that are exchanged between the SY(H)DFEE system and the higher-level control.

• In addition to the function described above, the device assumes the task of generating analog command values for pressure and swivel angle. The command values for swivel angle and pressure are provided via a ten-turn potentiometer that allows command values of 0 to ca. 120 % to be generated.

Before utilizing this function, make sure that the system is in an operationally safe condition so that an improper provision of command values will not result in personal injury of the operator or damage to the machine.

About this product 15/32


5.2 Product description

5.2.1 Block diagramThe block diagram is provided on the back of the device.

Fig. 1: Block diagram of the test device VT-PDFE-1-10/V0/0

5.2.2 Electrical connectionThe test device is provided with a socket and a cable connector in order to interconnect it in the supply cable to the VT-DFPx pilot valve of the SY(H)DFEE pump control system. The mating connector is to be plugged directly onto the pilot valve of the pump unit, the cable connector is to be connected to the incoming cable of the plot valve, which was disconnected beforehand. The connectors cannot be interchanged. • The pilot valve has not enable input to deliberately enable or disable the control function of the valve. The control becomes effective as soon as the pilot valve is supplied with power and the pump is powered, and the command values that are input are decisive for the operational states of pressure or swivel angle control.

1

2

3

EP

4

6

8

9

01

11

5

7

1

2

3

EP

4

6

8

9

01

11

5

7

UB / power supplyUBON/OFF

profecnerefer/0L ower supply

)V0=(rorre

llaroflaitnetopecnerefer/0M analog values

internal 0-10V

0-10Vinternal

external

external

swivel angle command value

αcommand

ppressure command value

com

pcommand

swivel angle actual value

p pressure actual valueact

switch TD (in) or power limiter activ (out)

p HIGH / signal (+) frompressure transducer

IST

p LOW / signal (-) frompressure transducer

IST

CLPmorfEEFDYSot

green

red

16/32 About this product


• The contacts on the mating connector must not be exposed to mechanical stress. This can lead to temporary or permanent damage to the connection between the mating connector and the plug-in connector.

Fig. 2: Protection of contacts

The test device has no own power source and utilizes the power supply of the pilot valve for its own energy supply.Operating the pump systems requires an external power supply as is the case for normal operation without this test device. Switch UB on the test device allows the power supply to the pilot valve to be switched on and off. When the power supply is available and switch UB is set to EIN (ON), the LED next to is lit green thus signaling that the pilot valve is supplied with voltage.The test device is not equipped with an electrical protection against overcurrent (e.g. micro-fuse). This applies to the implemented power supply and the signal cables. Fuses have to be provided on the system side.In the event of faults or when any work is to be carried out, the pilot valve can be disconnected from the power supply by means of switch UB.

CAUTION: In the case of systems with external supply, the safety function, which swivels the pump from zero stroke when the control valve is de-energized, is not effective.

▶ Switch also the drive motor of the pump off in the event of a fault!

Voltage supply



5.2.3 Front of test device

Fig. 3: Front view

The figure above shows the test device without the jumpers that are plugged in in the factory.

Switch UB can be used to interrupt the voltage supply to the pilot valve.The green LED next to the switch signals that voltage is supplied and the switch is turned to EIN (ON). In this case, the connected pilot valve is supplied with voltage.

The switch is used to select the signal source for the command values of “pressure” and “swivel angle” of the pump system.The following determination applies: • Position intern (= potentiometer) With this switch position the command values are provided by the two potentiometers installed in the test device and passed on to the output connector of the device. The command values are fed exclusively from the test

Ein

Aus

UB

UB

SOLL

SOLL

IST IST

SOLLp

SOLLp

p

Fehler

switch TD M0

ISTISTpp High

TSIp

HH

ISTp Low

L0

PE von SPS

nach SY DFEE

TSIp

L

intern

extern

Sollwert-vorgabe

Potentiometer for swivel angle command value active with Sollwertvorgabe - intern - (command value provision internal)

Potentiometer for pressure command value active with Sollwertvorgabe - intern - (command value provision internal)

Selection of command value source

Jumpers plugged (actual pressure value from pressure transducer)

Voltage supply Ein (ON)/Aus (OFF) with indicator lamp

Voltage supply EIN/AUS (ON/OFF)

Ein

Aus

UB

Sollwertvorgabe intern/extern (command value

provision internal/external)

intern

extern

Sollwert-vorgabe

18/32 About this product


device to the pilot valve or the pump system. In this case, any connected higher-level control has no influence on the command value feedforward to the pump system.

• Position extern (= external control) With this switch position the command values are fed from the input connector of the test device directly to the output connector of the device. This means that the higher-level control provides the command values for the pilot valve or the pump system, respectively. The test device merely serves as measuring instrument for all signals.

5.2.4 Measuring points

Fig. 4: Measuring points

The following has to be taken into account: • The reference for the voltage supply (socket “UB“) as well as the sockets “switch TD“ and “Fehler“ (error) is socket “L0“.

• The reference for the signal „pist High“ is socket “pist Low“. • The reference for all other variables to be measured is socket “M0“.

Ein

Aus

UB

UB

SOLL

SOLL

IST IST

SOLLp

SOLLp

p

Fehler

switch TD M0

ISTISTpp High

TSIp

HH

ISTp Low

L0

PE von SPS

nach SY DFEE

TSIp

L

intern

extern

Sollwert-vorgabe

Voltage supply UB

Swivel angle command value

Actual swivel angle value

Error message (0 V = error) with indicator lamp

Oil volume adjustment (changeover) switch TD

Actual pressure value from pressure

transducer (signal with reference)

Reference of UB

Ground

Pressure command value

Actual pressure value

Reference signal M0 for analog measuring variables

Upper pair of sockets: Actual pressure value to pilot valve (signal and reference)

Lower pair of sockets: Actual pressure value from pressure transducer (signal and reference)

Command value provision internal/external



• Depending on the variant of the pilot valve, the socket “switch TD“ can be a digital input (“switch TD“ = control signal to the valve/oil volume adjustment) or also a digital output (feedback from valve to the control “power limitation active”) (see operating instructions of the relevant DFE system).

Between the individual measuring sockets there must not be any connections. They might lead to short-circuits, malfunction or other defects!

5.2.5 Indicator lampsThe green LED next to switch UB signals that the voltage supply is available and that the switch is switched on. In this case, the connected pilot valve is supplied with voltage.

Next to the measuring socket “Fehler“ for the error signal, there is an LED that shows the current state of the error message. The switching signal is issued by the pilot valve and works according to the logic “low-active”, i.e. • the signal level 0 V (ore more exactly <1 V) means error • the signal level +24 V (or more exactly >13 V) means no error

5.2.6 PotentiometersTwo ten-turn potentiometers are integrated in the test device for the provision of a swivel angle command value (αSOLL) and a pressure command value (pSOLL). They are only activated, if the switch “Sollwertvorgabe“ (command value provision) is switched to position “intern” (internal).The adjustment range of the two potentiometers is from 0 V to ca. +12 V. The desired command values can be exactly set. The applied voltage can be measured at the two measuring sockets provided underneath (αSOLL and pSOLL / reference M0).

5.2.7 Jumpers

CAUTIONImpermissible operational states due to unplugging of jumpers!Risk of injury and risk of damage to property due to uncontrolled movements that result from the fact that no actual pressure value signal is sent to the pump control.

▶ Never unplug one of the two jumpers during operation.

The jumpers serve to split the actual pressure signal that is fed to the pilot valve via the central connection cable. The jumpers are included in the scope of delivery of the test device.The actual pressure value level (PISTH) is fed to the pilot valve with its own reference potential (PISTL). The lower pair of measuring sockets is connected with the connections of the higher-level control. The signal of the pressure transducer comes from here. The upper pair of sockets is constantly connected to the pilot valve at the pump unit.When the jumpers are removed, an actual pressure value signal from another pressure transducer may be fed forward to the pilot valve.

Green LED (UB)

Red LED (error)

SOLL SOLLp

TSIp

HH

von SPS

TSIp

L

nach SY DFEE

20/32 Transport and storage


In this case, the pressure signal must be connected to the upper pair of sockets (“nach SYDFEE”). It is important that both the signal (pISTH) and the reference (pISTL) are connected.For normal operation the two jumpers must always be plugged in.Exception: When the integrated pressure transducer HM20-2x is used, which is directly connected to the pilot valve by means of an M12 connection cable, the jumpers are irrelevant.

If you replace one of the two jumpers by looping in an amperemeter, the output signal can be measured directly, e.g. in the case of pressure transducers with current output.

5.3 Identification of the product

5.3.1 Information on the nameplate of the test deviceThe meaning of the information on the nameplate of the test device is explained in the correspondingly numbered fields of the following table.

Fig. 5: Nameplate of test device

1 Word mark 2 CE mark

3 Material short text 4 Manufacturer's factory number

5 Material number 6 Date of manufacture

7 Serial number 8 Designation of origin

6 Transport and storageThere are no special transport instructions for this product. However, observe the notes in chapter 2 “Safety instructions“. Bosch Rexroth recommends that the test device be stored in its original cardboard box.

SY2HDFEE-1X/125-045/R901038404+R90119184000120267633

7087

1

3

5

7

2

4

68

SY2HDFEE-1X/125-045/R901038404+R90119184000120267633

7087

VT-PDFE-1-1X/V0/0

MNR: R900757051 SN:ABC22874.0.a

7087

Made in Germany 19W01

Installation 21/32


7 Installation

NOTICECondensed water!Risk of short-circuit

▶ Allow the test device to acclimatize for several hours to prevent the formation of condensed water in the housing of the test device.

Penetrating humidity!The housing of the test device is enclosed. Nevertheless, according to the applicable ingress protection class, fluids may enter and lead to faults and short-circuit. This will result in the fact that safe operation of the test device can no longer be ensured.

▶ When working with the test device, always ensure that no fluids can enter the electronics housing.

Major potential differences!Risk of destroying the electronics by connecting or disconnecting plug-in connectors under voltage.

▶ Switch off the power supply to the relevant system part before assembling the device or when connecting and disconnecting connectors.

7.1 UnpackingDispose of the packaging in accordance with the national regulations of your country.

7.2 Installation conditions ▶ For installing the product always observe the environmental conditions

specified in the technical data sheet.

NOTICE: The environment must be free from aggressive substances (acids, bases, corrosive agents, salts, metal vapors, etc.) which may enter the device despite compliance with the relevant protection class.

▶ Before commissioning, make sure that all plug-in connections are correctly installed and undamaged to ensure that no fluids or foreign particles can enter the product.

7.3 Required toolsNo special tools are required for the installation.

7.4 Before use ▶ Before using the test device, check compliance of the type designation on the

nameplate with your order or job order number.

7.5 Place of useThe test device should not be installed next to power electronics (e.g. frequency converters, etc.)

22/32 Installation


7.6 Installing the test device for SY(H)DFEE systems

7.6.1 Installing the test device mechanically

CAUTIONInsufficient installation space!Insufficient space may lead to jamming or abrasions in case of actuation and adjustment work on the valve.

▶ Ensure sufficient space. ▶ Make sure that actuation and adjustment elements and plug-in connectors are

easily accessible.

Sharp edges!Sharp edges may be present at the place of installation of the valve to be tested. These may result in cutting or abrasive injuries during mounting/demounting.

▶ Wear the necessary personal protective equipment as required according to the place of use.

NOTICEFaulty installation of plug-in connectors, cables and measuring sockets!Improperly mounted connectors and measuring lines and cables may loosen and result in incorrect measurements.

▶ Only start with testing when you made sure that all connections are properly connected.

7.6.2 Connecting the test device electrically

CAUTIONFaulty energy supply!Risk of damage to property and personal injuries! Faulty energy supply of the test device may lead to uncontrolled valve settings. These could result in malfunctions or failure of the valve and cause injuries.

▶ Always connect the earthing connection of the valve with the appropriate earthing system in your installation.

▶ Only use a power supply unit with safe separation. ▶ Always observe the relevant national regulations.

Damage to property!Improperly laid cables and lines may lead to damage to the device and the system.

▶ Lay cables and lines so that they cannot be damaged and no one can trip over them.

Installation 23/32


CAUTIONMissing seals and fasteners!Risk of short-circuit! Fluids may enter the test device and cause a short-circuit.

▶ Before commissioning, make sure that all seals and plugs of plug-in connections are tight.

Incorrect connection wiring!Risk of injury due to electric shock and malfunctions! The test device may only be connected by or under the supervision of a specialized electrician.

▶ De-energize the connection line before the installation. ▶ Correctly connect the protective earthing conductor and the earthing. ▶ Ensure that there are no sharp bends in the connection line and litz wires to

avoid short-circuits and interruptions. ▶ Cable and line entries must always be assembled according to the assembly

instructions. ▶ During the installation, ensure tightness between the cable, cable entry and

line entry. ▶ The connection line(s) must be strain-relieved.

NOTICEMissing seals and fasteners!Loss of protection class IP20. Liquids and foreign particles may penetrate and damage the test device.

▶ Before using the device, make sure that all seals and fasteners of plug-in connections are tight.

Plugging or unplugging live connectors!The test device might be destroyed!

▶ Switch off the power supply to the relevant system part before installing the test device or when connecting or pulling connectors.

▶ Ensure maintenance-friendly connection, i.e. easy access to the connection lines. Free access to the connection sides must be guaranteed.

▶ For signal cables, use only cables with a copper braid shield.

▶ Do not route signal cables through strong magnetic fields. ▶ Lay signal lines as continuously as possible.

Shielding

General notes on wiring

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8 Commissioning

WARNINGImproper commissioning!Risk of damage to property and personal injuries. Commissioning of the test device requires basic knowledge in the field of hydraulics and electrics/electronics.

▶ The test device may only be commissioned by qualified staff.

8.1 Initial commissioning ▶ Only commission a completely connected product. ▶ Allow the test device to acclimatize for some time prior to commissioning as the

electronics might be damaged by the formation of condensed water.

9 Operation

CAUTIONMutual influencing of devices!Unforeseeable movements of the system!

▶ Make sure that neither the test device can be influenced by other devices nor other devices can be influenced by the test device.

Only specialist personnel who have electrical and hydraulic knowledge may operate the device in a controlled electromagnetic environment according to EN 61326-1.

10 Maintenance and repairTest devices from Bosch Rexroth are maintenance-free.

▶ Regularly check the product and the connections and measuring sockets for tight fitting at the housing! Loose connections (measuring sockets and connectors) can result in malfunctions.

▶ Replace the seals at reasonable intervals as a precautionary measure.

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10.1 Cleaning and care

NOTICEIngress of contaminants and humidity!Malfunction.

▶ Always ensure absolute cleanliness when working with the test device!

Solvents and aggressive cleaning agents!Damage and accelerated aging of the housing.

▶ Do not use aggressive cleaning agents for cleaning.

Proceed as follow for cleaning and care: ▶ Carry out a visual inspection and check that all lines and connections fit properly. ▶ Check all plug-in and clamping connections of the test device for correct fitting

and damage at least once a year. ▶ Inspect cables for rupture and crushes. Have damaged or defective cables

replaced immediately! ▶ Clean housing parts with a dry and dust-free cloth.

10.2 RepairFor safety reasons, unauthorized modification of the test device is not allowed! Repairs may only be carried out by Bosch Rexroth AG. For repair and maintenance work, send the device to the service address specified in chapter 16.1. Devices returned to Bosch Rexroth for repair have to be shipped in the original packaging, if possible.

10.3 Spare partsAt www.boschrexroth.com you can order spare parts directly in the eShop. When ordering spare parts, please state the material number of the relevant spare parts.

Table 5: Material numbers

Material numberR900757051 VT-PDFE-1-1X/V0/0 Test device

At www.boschrexroth.com/en/xc/service/spare-parts/index you can have spare parts listed that can be ordered and order them directly.

Please address all questions regarding spare parts to your responsible Rexroth Service partner.Bosch Rexroth AG Service Hydraulics Bgm.-Dr.-Nebel-Str. 897816 Lohr am Main Tel: +49 (0) 9352 - 40 50 [email protected]

For the addresses of foreign subsidiaries, please refer to www.boschrexroth.com/addresses

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11 Demounting and replacement

11.1 Required toolsNo special tools are required for demounting.

11.2 Preparing demounting

WARNINGRisk of injury by demounting parts under pressure and electric voltage!If you do not de-pressurize and de-energize the system before starting demounting, you may get injured and the product or system parts may be damaged!

▶ Decommission the entire system as described in the general instructions for the system.

▶ The system and all connected components must be brought to a safe state. In addition, the components must be switched off, de-pressurized, de-energized and secured against restarting.

11.3 Preparations for storage and further useTo prepare the test device for storage and further use, proceed as follows:

▶ Store the test device in the original packaging. ▶ Protect against dust and humidity.

12 Disposal

12.1 Environmental protectionCareless disposal of the test device may cause environmental pollution.

▶ Dispose of the product therefore in accordance with the currently applicable national provisions in your country.

▶ Please observe the following information for the environmentally friendly disposal of the test device.

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12.2 Return to Bosch Rexroth AGProducts manufactured by us can be returned to us free of charge for disposal. When returned, the products must not contain any inappropriate foreign substances or third-party components. The components have to be sent carriage paid to the following address:Bosch Rexroth AGService IndustriehydraulikBürgermeister-Dr.-Nebel-Strasse 897816 Lohr am MainGermany

12.3 PackagingUpon request, reusable systems can be used for regular deliveries.The materials for disposable packaging are mostly cardboard, wood, and expanded polystyrene. They can be recycled without any problems. For ecological reasons, disposable packaging should not be used for returning products to Bosch Rexroth.

12.4 Materials usedHydraulic components from Bosch Rexroth do not contain any hazardous materials that could be released during intended use. In the normal case, no negative effects on human beings and on the environment have to be expected.The service case with test device basically consists of: • Aluminum • Copper • Plastics • Electronics components and assemblies • Elastomers

12.5 RecyclingVarious components can be recycled. In order to achieve an ideal recovery, disassembly into individual assemblies is required. The metals contained in electrical and electronic assemblies can also be recovered by means of special separation procedures. If the products contain batteries or accumulators, they have to be removed before recycling and furnished to the battery recycling, if possible.

13 Extension and modificationThe test device and its accessories must be neither extended nor converted. Modification of the test device will lead to expiry of warranty.

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14 Troubleshooting

14.1 How to proceed for troubleshooting ▶ Have defects rectified exclusively by specialist personnel of Bosch Rexroth AG. ▶ Try to get a clear idea of the cause of error.

14.1.1 Indicators and alarmsThe test device is not provided with indicators or alarms for its own error diagnostics. The LED indicator lamps only serve for error diagnostics of the connected valves.

15 Technical dataFor applications outside these parameters, please consult us.

Operating voltages

Operating voltage UB V 24; -5 % +40 %

Current consumption of test device I A 0.1

Inputs

Actual pressure value input at pin 10 + 11 According to the valve data

Additional function at pin 9 According to the valve data

Pressure command value at pin 7 Internal: potentiometer 0 to 12 VExternal: according to the valve data

Reference potential at pin 4

Swivel angle command value at pin 5 Internal: potentiometer 0 to 12 VExternal: according to the valve data

Outputs

Errors at pin 3 Logical 2 4 V (0 V = error)

Actual swivel angle value at pin 7 According to the valve’s actual value output

Actual pressure value at pin 8 According to the valve’s actual value output

Additional function at pin 9 According to the valve’s actual value output

General

Dimensions of housing (W x H x D) mm 85 x 65 x 150

Weight m kg 0.82

Length of connection cables l m 2

Degree of protection IP 20

Ambient temperature range t °C 0...+50

Annex 29/32


16 Annex

16.1 List of addresses

Bosch Rexroth AGService IndustriehydraulikBürgermeister-Dr.-Nebel-Strasse 897816 Lohr am MainGermany

Phone +49 (0) 9352/40 50 60E-mail [email protected]

Outside Germany you will find service subsidiaries in your vicinity on the Internet at www.boschrexroth.com

Bosch Rexroth AGZum Eisengießer 197816 Lohr am MainGermany

Phone +49 (0) 9352/40 30 20Email [email protected]

The addresses of our sales and service network and sales organizations can be found at www.boschrexroth.com/addresses

Contact for service and spare parts

Headquarters

30/32 Alphabetical index


17 Alphabetical index

▶ BBlock diagram 15

▶ CCleaning and care 25Commissioning 24Connecting the test device electrically 22

▶ DDamage to property 13Demounting and replacement 26Designations 6Disposal 26

▶ EElectrical connection 15Environmental protection 26Equipotential bonding 11Extension and modification 27

▶ HHazard classifications according to ANSI Z535.6-2011 6

▶ IIdentification of the product 20Improper use 7Indicator lamps 19Installation 21Installing the test device 22Intended use 7IP protection class 11

▶ JJumpers 19

▶ LList of addresses 29

▶ MMaintenance and repair 24Measuring points 18

▶ NNameplate 20

▶ OOperation 24

▶ PPackaging 27PE connection 11Performance description 14Potentiometers 19

▶ QQualification 7

▶ RRecycling 27Repair 25Required documentation 5Return to Bosch Rexroth AG 27

▶ SSafety instructions 7 – general 8 – product-specific 9 – Signal word 6

Scope of delivery 14Spare parts 25Storage 26Symbols 6

▶ TTechnical data 28Tools 21Training 8Transport and storage 20Troubleshooting 28

▶ UUse – improper 7 – intended 7

▶ WWarranty 13

Alphabetical index 31/32


Bosch Rexroth AGIndustrial HydraulicsZum Eisengießer 197816 Lohr a. MainGermanyPhone +49 (0) 9352/40 30 [email protected]

Subject to revision

Printed in Germany

RE 29689-B/11.2019

Test device for control system SY(H)DFEE

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Transcript of Test device for control system SY(H)DFEE