Bosch rexroth CytroForce-M User manual

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

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. All rights are reserved with respect to the content of this
documentation and the availability of the product.
1d690e74316346200a347e886cad618f, 1, en_US

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Servo-hydraulic actuator
Bosch Rexroth AG
RE62270-B,
01.21
Table of contents
1 About this documentation 5
1.1 About this documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Required and supplementary documentation. . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Representation of information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety instructions 11
2.1 About this chapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Product-specific safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Obligations of the machine end-user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 General information on damage to property and damage to the product 17
4 Scope of delivery 19
5 About this product 21
5.1 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.2 Types of design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.3 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.4 Solution matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.5 System Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.6 Custom extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.7 Technology function PFC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.8 Functional safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Identification of the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2.1 Nameplate of the servo-hydraulic actuator. . . . . . . . . . . . . . . . . . . . . 29
5.2.2 Nameplates of main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Technical interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3.1 Mechanical interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3.2 Electrical interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3.3 Software interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3.4 Hydraulic interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Transport and storage 33
6.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 Installation 37
7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.2 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3 Installation conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.1 Drive unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.2 Drive controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.3 Cable set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.4 Installation orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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RE62270-B,
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7.5 Mounting the servo-hydraulic actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5.1 Preparing the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5.2 Mechanical mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5.3 Hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.5.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Commissioning 45
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.2 Software commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.3 Commissioning of optional safety technology. . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4 Test sequence for validating the safety functions. . . . . . . . . . . . . . . . . . . . . . . 49
8.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4.2 Axis validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4.3 Machine acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.4.4 Escalation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9 Operation 55
9.1 Operational states. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.1.1 Operational states. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2 Error management and event management. . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.2.1 Error management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.2.2 Event management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3 Diagnostic messages of the application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.4 Field data acquisition (FDA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10 Maintenance and repair 61
10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.2 Cleaning and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.3 Maintenance and inspection schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.4 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.5 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.6 Replacement of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11 Demounting and removal 67
11.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.2 Preparing demounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.3 Demounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.4 Storage / further use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.5 Replacement of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
12 Disposal 69
13 Extension and modification 71
14 Troubleshooting 73
14.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14.2 How to proceed for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14.3 General error list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
15 Technical data 75
16 Annex 77
16.1 Service and support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
16.2 Declaration of incorporation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17 Index 83

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Servo-hydraulic actuator
Required and supplementary documentation
Bosch Rexroth AG
RE62270-B,
01.21
1 About this documentation
1.1 About this documentation
This documentation is valid for the following products:
●Servo-Hydraulic Actuator "CytroForce-M"
A detailed product description can be found in ⮫ Chapter 5 “About this
product” on page 21. For the exact scope of delivery of the servo-hydraulic
actuator ordered by you, please refer to your order confirmation.
This documentation is intended for fitters, operators, service technicians,
project planners, and plant operators. This documentation contains important
information on the safe and proper mounting, transport, commissioning, opera-
tion, use, maintenance, demounting and simple troubleshooting of the servo-
hydraulic actuator. Read this documentation completely and thoroughly, espe-
cially ⮫ Chapter 2 “Safety instructions” on page 11, before working with the
product.
1.2 Required and supplementary documentation
The product must not be commissioned until you have been provided with the
documentation marked with the book symbol and you have understood and
observed it.
Title Document
number
Document type
System documentation from the system manu-
facturer
General informa-
tion on the com-
plete system
Order confirmation Shows the scope
of supply
Wiring diagram (description of system struc-
ture and interfaces)
Schematic dia-
gram
Installation drawing Layout plan
Hydraulic circuit diagram Schematic dia-
gram
Declaration of incorporation for the servo-
hydraulic actuator
Document ⮫ Chapter 16.2
“Declaration of
incorporation”
on page 78
Servo-hydraulic actuator CytroForce-M Inte-
grated or CytroForce-M Split
R: 62280, R.
62282
Data sheet
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
PSB
R911328651 Parameter
description

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Servo-hydraulic actuator
Required and supplementary documentation
Bosch Rexroth AG
RE62270-B,
01.21
Title Document
number
Document type
Rexroth IndraDrive MPx-16 to MPx- 20 and
PSB
R911326738 Description of
diagnostic mes-
sages
Rexroth IndraDrive Integrated Safety Tech-
nology "Safe Motion" (as of MPx-18)
R911338920 Application
manual
Rexroth Sytronix SvP 7020 PFC Variable-
Speed Positioning of Hydraulic Axes
R: 62313-FK Commissioning
Manual
IndraDrive Control Sections CSB02, CSE02,
CSH02, CDB02
R911338962 Project Planning
Manual
Rexroth IndraDrive Supply Units, Power Sec-
tions HMV, HMS, HMD, HCS02, HCS03
R911318790 Project Planning
Manual
Rexroth IndraDrive Drive Systems with
HMV01/02 HMS01/02, HMD01, HCS02/03
R911309636 Project Planning
Manual
IndraDyn S Synchronous Servo Motors MS2N R911347583 Project planning
manual
IndraDyn S Synchronous Motors MS2N R911347581 Operating instruc-
tions
Rexroth IndraDrive Additional Components
and Accessories
R911306140 Project planning
manual
Maintenance kit for servo-hydraulic actuators
SY-SHA
R: 62249-B Operating instruc-
tions
Control cabinet: Air Conditioning, EMC,
Design, IP Code, Electrics, IndraDrive, Rexroth
EFC/Fv, Sytronix
R911344988 Project Planning
Manual
Motor cables and connections with IndraDrive R911401938 Catalog
Mating connectors and cable sets for valves
and sensors
R: 08006 Data sheet
2-way cartridge valves with spool position
monitoring, passively controlled
R: 21015 Data sheet
Directional spool valves, direct operated, with
solenoid actuation
R: 23178 Data sheet
2/2, 3/2 and 4/2 directional seat valves with
solenoid actuation
R: 22049 Data sheet
Directional spool valves, direct operated, with
solenoid actuation
R: 23340 Data sheet
Maintenance indicator for filters, type WE and
WO
R: 51450 Data sheet
Pressure transducer for hydraulic applica-
tions, type HM20-2x
R: 30272-MON Installation
instructions
Bladder-type accumulator, type HAB..-6X R: 50171-B Operating instruc-
tions

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Servo-hydraulic actuator
Representation of information
Bosch Rexroth AG
RE62270-B,
01.21
Title Document
number
Document type
Diaphragm-type accumulator, type HAD R: 50150 Data sheet
Pressure relief valve, direct operated, type
DBD
R: 25402 Data sheet
Temperature sensor IFM TA2105 see website of
the manufacturer,
ifm
A part of the documentation listed above is also stored on the microSD card
that is included in the scope of delivery.
1.3 Representation of information
In 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, they are explained in the following sections.
Safety instructions
In this documentation, safety instructions are contained in ⮫ Chapter 2.6
“Product-specific safety instructions” on page 13 and ⮫ Chapter 3 “General
information on damage to property and damage to the product” on page 17
and wherever sequences of actions or instructions are explained which bear
the risk of personal injury or damage to property. The hazard avoidance meas-
ures described must be observed.
Safety instructions are structured as follows:
WARNING Type and source of danger! and consequences in the
case of non-observance
−Hazard avoidance measures
●Warning symbol: draws attention to a hazard
●Signal word: identifies the degree of hazard
●Type and source of danger!: identifies the type and source of hazard
●Consequences: describes the consequences in case of non-compliance
●Precautions: states, how the hazard can be avoided
DANGER In case of non-compliance with this safety instruction,
death or serious injury will occur.
WARNING In case of non-compliance with this safety instruction,
death or serious injury could occur.
CAUTION In case of non-compliance with this safety instruction,
minor or moderate injury could occur.
NOTICE In case of non-compliance with this safety instruction,
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

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Servo-hydraulic actuator
Representation of information
Bosch Rexroth AG
RE62270-B,
01.21
Designation Meaning
Sercos III 3. Generation of the Sercos interface
series (digital drive interface)
EhterCAT Ethernet for Control Automation
Technology
Profinet Process Field Network
PROFIBUS Process Field Bus
EtherNet/IP EthernetNet Industrial Protocol
Abbreviations used
The following terms are used in this documentation:
Table 2: Abbreviations
Designation Meaning
IO Inputs / outputs
EN European Standard
Ex Explosion protection
FDA Field Data Aquisition
FKM Führungskommunikation (master
communication)
GND Chassis Ground
HW Hardware
IEC International Electrotechnical Com-
mission
IP Ingress Protection
ISO International Organization for Stand-
ardization
NC Normally closed
NO Normally open
L1, L2, L3 Phase conductors
PE Protective Earth
PFC Position Force Control
SHA Self-contained servo-hydraulic linear
axis
PLC / MLD Programmable Logic Control
A/F Software
TN-C-S Terre Neutre Combiné Séparé
VDC Volts of Direct Current

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Servo-hydraulic actuator
Representation of information
Bosch Rexroth AG
RE62270-B,
01.21
Designation Meaning
VAC Volt Alternating Current
Vpp Peak-peak value of a voltage source

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Servo-hydraulic actuator
Representation of information
Bosch Rexroth AG
RE62270-B,
01.21