Bosch rexroth CytroForce-M Operating Manual
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Bosch rexroth CytroForce-M Operating Manual

Servo-hydraulic actuator
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Operating Manual
Servo-hydraulic actuator
CytroForce-M
RE62270-B, 01.21

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Summary of Contents for Bosch rexroth CytroForce-M

  • Page 1 Operating Manual Servo-hydraulic actuator CytroForce-M RE62270-B, 01.21...
  • Page 2 Copyright © Bosch Rexroth AG Bosch Rexroth AG© 2021 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract.

  • Page 3: Table Of Contents

    Accessories........... . RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 4 16.2 Declaration of incorporation........17 Index Bosch Rexroth AG RE62270-B, 01.21...

  • Page 5: About This Documentation

    R: 62280, R. Data sheet grated or CytroForce-M Split 62282 Hydraulic valves for industrial applications R: 07600-B Operating instruc- tions Rexroth IndraDrive MPx-20 Functions R911345608 Application manual Rexroth IndraDrive MPx-16 to MPx- 20 and R911328651 Parameter description RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 6 Data sheet solenoid actuation Maintenance indicator for filters, type WE and R: 51450 Data sheet Pressure transducer for hydraulic applica- R: 30272-MON Installation tions, type HM20-2x instructions Bladder-type accumulator, type HAB..-6X R: 50171-B Operating instruc- tions Bosch Rexroth AG RE62270-B, 01.21...

  • Page 7: Representation Of Information

    In case of non-compliance with this safety instruction, NOTICE property damage could occur. Designations The following terms are used in this documentation: Table 1: Designations Designation Meaning IndraWorks Ds Bosch Rexroth service tool for drive commissioning RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 8 Normally closed Normally open L1, L2, L3 Phase conductors Protective Earth Position Force Control Self-contained servo-hydraulic linear axis PLC / MLD Programmable Logic Control Software Terre Neutre Combiné Séparé TN-C-S Volts of Direct Current Bosch Rexroth AG RE62270-B, 01.21...
  • Page 9 Servo-hydraulic actuator 9 / 85 Representation of information Designation Meaning Volt Alternating Current Peak-peak value of a voltage source RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 10 Servo-hydraulic actuator 10 / 85 Representation of information Bosch Rexroth AG RE62270-B, 01.21...

  • Page 11: Safety Instructions

    Improper use Any use deviating from the intended use is improper and thus not admissible. Bosch Rexroth AG does not assume any liability for damage caused by improper use. The user assumes all risks involved with improper use. RE62270-B, 01.21...

  • Page 12: Qualification Of Personnel

    This knowledge can be acquired in specific training courses. Bosch Rexroth offers training courses that support your qualification in specific fields. You can find an overview of training contents on the Internet at: ⮫ http:// www.boschrexroth.com General safety instructions ●...

  • Page 13: Product-Specific Safety Instructions

    ● Only use original Bosch Rexroth accessories and spare parts in order to pre- vent any hazard to persons due to unsuitable spare parts.
  • Page 14 Combustible hydraulic fluid! Risk of fire. WARNING − Keep open fire and ignition sources away from the servo-hydraulic actuator. − Ensure sufficient ventilation. − Do not carry out welding work on or in the vicinity of servo-hydraulic actuator. Bosch Rexroth AG RE62270-B, 01.21...

  • Page 15: Personal Protective Equipment

    ● the actuator is only stored, operated and maintained according to the speci- fied operating and environmental conditions, in particular that the specified limit values are not exceeded. ● the operating personnel are instructed at regular intervals. ● a danger zone is marked, if required. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 16 The operation of installations, systems and machines basically requires the implementation of a holistic IT security concept which is state-of-the-art in terms of technology. Accordingly, Bosch Rexroth products and their properties must be considered as components of installations, systems and machines for their holistic IT security concept.

  • Page 17: General Information On Damage To Property And Damage To The Product

    − Dispose of the hydraulic fluid in accordance with the national regulations in your country. − Please immediately contact Bosch Rexroth Service, see ⮫ Chapter 16.1 “Service and support” on page 77. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 18 Mixing of hydraulic fluids! Mixing of hydraulic fluids of NOTICE different make or different types of the same make is not permitted! − Observe the notes given by the fluid manufacturers of the hydraulic fluids used. Bosch Rexroth AG RE62270-B, 01.21...

  • Page 19: Scope Of Delivery

    ● Inspect the scope of delivery for any transport damage, see ⮫ Chapter 6 “Transport and storage” on page 33. In case of complaints, please contact Bosch Rexroth AG, see ⮫ Chapter 16.1 “Service and support” on page 77. RE62270-B, 01.21...
  • Page 20 Servo-hydraulic actuator 20 / 85 Bosch Rexroth AG RE62270-B, 01.21...

  • Page 21: About This Product

    These functions are provided via the safety technology integrated in the drive controller. The servo-hydraulic actuator communicates with the higher-level machine control over a field bus system. The main components are described in the following. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 22 The following figures may differ from your individual axis depending on the selected configuration. − The “split” version is also offered as piped variant. In this case, the cylinder is not flanged (optional). Fig. 1: Product description of CytroForce-M Integrated Bosch Rexroth AG RE62270-B, 01.21...
  • Page 23 Motor/pump group The motor/pump group makes hydraulic power available in line with demand. Manifold block The switching logic for the optional rapid/force mode changeover and for the optional safety valves is integrated in the control block. RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 24: Solution Matrix

    For a functional description, parameter description and description of diag- nostic messages of the drive controller, please refer to the related Bosch Rexroth documentation, see also ⮫ Chapter 1.2 “Required and supplementary documentation” on page 5.

  • Page 25: System Structure

    A comprehensive portfolio of custom extensions is available for the servo- hydraulic actuator. Safety on board The safety modules HSZ01, HAT02 and Safe Motion S4, which can be perfectly integrated, allow the economic implementation of safety functions in accord- ance with standards. RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 26: Technology Function Pfc

    Further information can be found in the commissioning instructions "Rexroth Sytronix SvP 7020 PFC Variable-Speed Positioning of Hydraulic Axes”, R.62313- FK, ⮫ Chapter 1.2 “Required and supplementary documentation” on page 5. Bosch Rexroth AG RE62270-B, 01.21...

  • Page 27: Functional Safety

    ISO 13849-1 Category 3, PL d and IEC 62061 SIL 2, and safety functions inde- pendent of an encoder are applicable according to ISO 138491 Category 4, PL e and IEC 62061 SIL 3. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 28 (HSZ01) or via a safe field bus at the Multi-Ethernet inter- face (ET). Safety-capable encoder system and encoder evaluation In the case of encoder-dependent safety functions the selection of the encoder system on the load side is decisive. The safety-capable encoder system must Bosch Rexroth AG RE62270-B, 01.21...

  • Page 29: Identification Of The Product

    Identification of the product 5.2.1 Nameplate of the servo-hydraulic actuator Fig. 7: CytroForce-M nameplate Type of information Manufacturer's logo Material number Type designation Manufacturer's factory number Date of production Designation of origin Customer job order RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 30 Position of the CytroForce-M nameplate The following figure shows the respective position of the nameplate of the servo-hydraulic actuator types CytroForce-M Split and Integrated. Fig. 8: Position of nameplate CytroForce-M Integrated, top CytroForce-M Split, side, (central nameplate) Bosch Rexroth AG RE62270-B, 01.21...

  • Page 31: Nameplates Of Main Components

    The following Ethernet field bus systems are available: ● CIP Safety on Sercos (as of firmware version MPx18VRS) ● Safety over EtherCAT (as of firmware version MPx20VRS) ● PROFIsafe on PROFINET (as of firmware MPx20VRS) RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 32: Software Interfaces

    Any work (e.g. connection, maintenance) on the hydraulic interfaces may exclu- sively be carried out by Bosch Rexroth or by authorized and trained personnel, see ⮫ Chapter 2.4 “Qualification of personnel” on page 12.

  • Page 33: Transport And Storage

    − Converters and supply units: Operation with mains voltage − Inverters and DC bus capacitor units: Operation with DC bus voltage The assemblies should preferably be stored in the unopened original pack- aging. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 34 ● Check the assemblies for proper function and leaks during a test run. If the actuator has to be stored over a period longer than the time given in the above table “Storage times”, contact Bosch Rexroth with regard to the preser- vation and later commissioning of the servo-hydraulic actuator.
  • Page 35 Since deformation of seals cannot be ruled out, replace seals. Observe ⮫ Chapter 11.5 “Replacement of components” on page 68. Should you have any queries, please contact Bosch Rexroth Service. Pack the assemblies air-tight together with a desiccant in an anti-corro- sion foil.
  • Page 36 Servo-hydraulic actuator 36 / 85 Storage Bosch Rexroth AG RE62270-B, 01.21...

  • Page 37: Installation

    − Wear your personal protective equipment such as safety shoes and gloves. − Contact Bosch Rexroth for proper refilling of the servo-hydraulic actuator. Incorrect connection of electric components. Risk of NOTICE short-circuit and damage! −...

  • Page 38: Installation Conditions

    R961013500 Observe the operating instructions R. 62249-B with regard to the maintenance kit for servo-hydraulic actuators (SY-SHA). Regarding accessories, please contact Bosch Rexroth Service for clarification; see ⮫ Chapter 16.1 “Service and support” on page 77. Bosch Rexroth AG RE62270-B, 01.21...

  • Page 39: Mounting The Servo-Hydraulic Actuator

    If the material numbers or denominations of the servo-hydraulic actuator and of the drive controller do not correspond to those given in the order confirmation, contact Bosch Rexroth Service for clarification, see ⮫ Chapter 16.1 “Service and support” on page 77.

  • Page 40: Hydraulic Installation

    The servo-hydraulic actuator is a self-contained system. A service interface to the service kit is available and also necessary. Any required work (adjustment work, inspection for leakage, etc.) is carried out by Bosch Rexroth before dis- patch. Bosch Rexroth AG...

  • Page 41: Electrical Installation

    Bosch Rexroth or by authorized and qualified per- sonnel of a specialized company that was authorized by Bosch Rexroth, see ⮫ Chapter 2.4 “Qualification of personnel” on page 12. − Please observe the general installation and safety reg- ulations when working on high-voltage systems.
  • Page 42 ● Renew cable markings and warning notes on cable connections which have become illegible or were lost. Bosch Rexroth AG RE62270-B, 01.21...
  • Page 43 ● Connect the shield of analog signal cables over a large surface area on one end, usually in the control cabinet. Ensure an short connection over a large area to the ground / housing. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 44 Connect the electrical components according to the wiring diagram. − Wiring and connection work may only be carried out by Bosch Rexroth or by authorized and qualified per- sonnel. Before starting to electrical cabling of the servo-hydraulic actuator, the fol- lowing work must have been completed: ●...

  • Page 45: Commissioning

    Filling the "Split" variant with hydraulic fluid The “Split” variant is shipped without hydraulic fluid fill. Bosch Rexroth has to fill the servo-hydraulic actuator with hydraulic fluid. In this respect, contact Bosch Rexroth Service, see ⮫ Chapter 16.1 “Service and support” on page 77.

  • Page 46: Software Commissioning

    �� Creation of a “good condition fingerprint” based on the measured sig- nals, e.g. noise measurement The stepwise re-commissioning of the servo-hydraulic actuator after malfunc- tion was rectified must always be agreed with Bosch Rexroth. Software commissioning General For commissioning the servo-hydraulic actuator no special activities are required, since all the necessary settings of hardware and software were made in the factory.

  • Page 47: Commissioning Of Optional Safety Technology

    Before a machine may be placed on the market, the manufacturer of the machine has to conduct a risk assessment in accordance with Machinery Direc- tive 2006/42/EC in order to determine the hazards related to operation of the machine. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 48 “Rexroth IndraDrive Integrated Safety Technology "Safe Motion" (as of MPx-18)”, 911338920, see ⮫ Chapter 1.2 “Required and supplementary documentation” on page 5. The following graphic roughly represents the individual commissioning steps: Bosch Rexroth AG RE62270-B, 01.21...

  • Page 49: Test Sequence For Validating The Safety Functions

    Before it is allowed to use a servo-hydraulic in a safety-related application, the axis must have been successfully validated. To meet the requirements of any application, the axis may be validated in four ways: RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 50: Machine Acceptance

    Special mode “Safe motion” If special “Safe motion” modes are configured, they can be accepted according to the documentation mentioned above. The following checks have to be carried out according to the configuration: Bosch Rexroth AG RE62270-B, 01.21...

  • Page 51: Escalation

    In the subsequent steps you can verify whether the escalation level of safe standstill from the function of STO with SBC until a functional standstill of the servo-hydraulic actuator takes place within a sufficient time. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 52 The proceeding is described using a tandem cylinder as an example. For other cylinder types (see hydraulic diagram) the proceeding may differ. In this case, contact Bosch Rexroth. The safety functions have to be configured so that in case of a fault the motor does not actively reduce the flow.
  • Page 53 ● P-0-3258, SMO: Actual velocity value ● P-0-3231, SMO: Operational state, bit 1 and bit 2 With this configuration, the acceptance for the special mode “Safe stand- still” can be carried out according to the documentation: Fig. 15: Esalation3 RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 54 Servo-hydraulic actuator 54 / 85 Test sequence for validating the safety functions Bosch Rexroth AG RE62270-B, 01.21...

  • Page 55: Operation

    Diagnostic parameters of the PFC technology functions: ● The diagnostic code is stored in parameter P-0-1300. ● The diagnostic text is stored in parameter P-0-1387, and is available in Eng- lish language only. Diagnostic parameters of the IndraDrive firmware: RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 56: Operational States

    The servo-hydraulic actuator provides an operating state control, which is largely based on the device control and state machine of the IndraDrive firm- ware. The operating states of the actuator are shown in the following in a strongly simplified form. Bosch Rexroth AG RE62270-B, 01.21...

  • Page 57: Error Management And Event Management

    These events are automatically reset when the cause has been eliminated. Warnings that are only present tempora- rily are signaled for a configurable minimum time (e.g. 5 s, specific to the application at hand). RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 58: Event Management

    The various diagnostic messages are subdivided into four categories, which are an integral part of the relevant diagnostic code. Errors und warnings trigger corresponding diagnostic messages in IndraDrive, whereas messages are diag- nosed exclusively via the parameters of the technology function. Bosch Rexroth AG RE62270-B, 01.21...

  • Page 59: Field Data Acquisition (Fda)

    This type of parameters should be optimized exclusively by Bosch Rexroth or by authorized and qualified personnel of a specialized company that was author- ized by Bosch Rexroth, see ⮫...
  • Page 60 Servo-hydraulic actuator 60 / 85 Field data acquisition (FDA) Bosch Rexroth AG RE62270-B, 01.21...

  • Page 61: Maintenance And Repair

    For cleaning and care, please observe the following: ● Plug all openings with suitable protective caps/devices. ● Check that all seals and plugs of the plug-in connections are tightly seated to ensure that no moisture can enter the drive unit during cleaning. RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 62: Maintenance And Inspection Schedule

    The time intervals mainly depend on the oper- ating conditions and the external environmental conditions (e.g. dirt, tempera- ture, vibration). The individual maintenance steps are described in the next chapter. Bosch Rexroth AG RE62270-B, 01.21...
  • Page 63 Bosch Rexroth recommends that the servo-hydraulic actuator be inspected annually by Bosch Rexroth Service. In this inspection the current condition of the servo-hydraulic actuator is checked and an oil sample is taken. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 64 What? Remarks Checking the gas pressure of the Maintenance work my only be carried accumulator out by Bosch Rexroth or authorized qualified personnel, see Replacing the filter element ⮫ Chapter 2.4 “Qualification of per- sonnel” on page 12. Taking oil samples, topping up oil For maintenance and repair work we offer a comprehensive selection of service tools (e.g.

  • Page 65: Repair

    The hydraulic circuit may only be opened by specifi- cally trained personnel. Bosch Rexroth has an extensive service offer regarding repairs. Should you have any queries, please contact Bosch Rexroth Service, see ⮫ Chapter 16.1 “Service and support” on page 77 10.5...
  • Page 66 Servo-hydraulic actuator 66 / 85 Replacement of components Bosch Rexroth AG RE62270-B, 01.21...

  • Page 67: Demounting And Removal

    − If the servo-hydraulic actuator is to be put out of operation or demounted, inform Bosch Rexroth or have this work carried out by Bosch Rexroth. 11.2 Preparing demounting It is possible to backup parameters. For information on reading parameter backups, please see the Application Manual of MPx-20, ⮫...

  • Page 68: Demounting

    They are provided with a hydraulic connection. For details, see hydraulic circuit diagram and operating instructions “Maintenance kit for servo- hydraulic actuators SY-SHA”, R.62249-B. In case of uncertainties or for further information, please contact Bosch Rexroth Service. Bosch Rexroth AG...

  • Page 69: Disposal

    Upon request, reusable systems can be used for regular deliveries. The mate- rials for disposable packaging are mostly cardboard, wood, and expanded poly- styrene. They can be recycled without any problems. For ecological reasons, disposable packaging should not be used for returning products to Bosch Rexroth. Materials used Hydraulic components from Bosch Rexroth do not contain any hazardous mate- rials that could be released during use according to the intended purpose.
  • Page 70 Servo-hydraulic actuator 70 / 85 Bosch Rexroth AG RE62270-B, 01.21...

  • Page 71: Extension And Modification

    Servo-hydraulic actuator 71 / 85 Extension and modification Loss of warranty! Personal injury and damage to prop- WARNING erty! − Modifications exceeding the extent described in these operating instructions are not permitted. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 72 Servo-hydraulic actuator 72 / 85 Bosch Rexroth AG RE62270-B, 01.21...

  • Page 73: Troubleshooting

    14.2 How to proceed for troubleshooting ● Troubleshooting may exclusively be carried out by Bosch Rexroth or by authorized and qualified personnel of a specialized company that was authorized by Bosch Rexroth. Moreover, training is required with regard to IndraDrive and the servo-hydraulic actuators.

  • Page 74: General Error List

    Low pressure warning of High external system leakage, Localize leakage accumulator leakage of gas pressure accumu- Contact Bosch Rexroth Service. lator Defective component, increased Localize leakage generation of noise Contact Bosch Rexroth Service. Malfunction or destruction...

  • Page 75: Technical Data

    75 / 85 Technical data The technical data can be found in the installation drawing, the data sheets of the servo-hydraulic actuator and the documentations from ⮫ Chapter 1.2 “Required and supplementary documentation” on page 5. RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 76 Servo-hydraulic actuator 76 / 85 Bosch Rexroth AG RE62270-B, 01.21...

  • Page 77: Annex

    ● Detailed description of the fault and the circumstances ● Details on the nameplate of the affected products, especially type code and serial number ● Your contact details (phone and fax number, e-mail address) RE62270-B, 01.21 Bosch Rexroth AG...

  • Page 78: Declaration Of Incorporation

    Servo-hydraulic actuator 78 / 85 Declaration of incorporation 16.2 Declaration of incorporation Fig. 17: Declaration of incorporation 1 Bosch Rexroth AG RE62270-B, 01.21...
  • Page 79 Servo-hydraulic actuator 79 / 85 Declaration of incorporation Fig. 18: Declaration of incorporation 2 RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 80 Servo-hydraulic actuator 80 / 85 Declaration of incorporation Fig. 19: Declaration of incorporation 3 Bosch Rexroth AG RE62270-B, 01.21...
  • Page 81 Servo-hydraulic actuator 81 / 85 Declaration of incorporation Fig. 20: Declaration of incorporation 4 RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 82 Servo-hydraulic actuator 82 / 85 Declaration of incorporation Bosch Rexroth AG RE62270-B, 01.21...

  • Page 83: Index

    Mechanical interfaces....31 Mechanical mounting....39 RE62270-B, 01.21 Bosch Rexroth AG...
  • Page 85 Bosch Rexroth AG Drives and Controls Zum Eisengiesser 1 97816 Lohr am Main +49 9352 40 30 20 my.support@boschrexroth.com www.boschrexroth.com RE62270-B RE62270-B...

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