Bosch Rexroth Sytronix FcP 5020 User manual

Sytronix
FcP 5020
Frequency-Controlled Pump Drive System
Quick Start Guide
R912006684
Edition 02

Bosch Rexroth AG FcP 5020
Record of Revision
Edition Release Date Notes
DOK-RCON03-FcP5020*Eco-QU01-EN-P 2016.03 Preliminary
DOK-RCON03-FCP5020****-QU02-EN-P 2016.09 New functions
Version Matching Table
Frequency converter EFC 5610 firmware version ASF version
03V12 01V04 or 01V06
03V14
03V18 and above 01V08
Introduction of this Documentation
This Quick Start Guide is derived from the Operating Instructions which in-
cludes the product data in details.
Personal injury and property damage caused by
incorrect application, installation or operation!
WARNING
Never work with or control the product before reading through
●Safety Instructions which delivered with EFC 5610
●Safety descriptions in the Operating Instructions
Reference
For documentation available in other type or language, please consult your local
sales partner or check www.boschrexroth.com.
Copyright
© Bosch Rexroth (Xi'an) Electric Drives and Controls Co., Ltd. 2016
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth (Xi'an) Electric Drives
and Controls Co., Ltd. It may not be reproduced or given to third parties without
its consent.
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 documen-
tation and the availability of the product.
RS-95773a12ad36be1c0a347ea500f43669-2-en-US-20

Table of Contents
Page
1 Type Code.............................................................................................. 1
1.1 Frequency Converter Type Code Description........................................ 1
1.2 FcP 5020 ASF Type Code Description................................................... 2
2 Scope of Supply..................................................................................... 4
3 Documentation Reference .................................................................... 4
4 Function Specification........................................................................... 5
5 Initial Start Up....................................................................................... 7
6 Electric Connection............................................................................. 10
6.1 Overview.............................................................................................. 10
6.2 Analog Input......................................................................................... 11
6.3 Analog Output...................................................................................... 13
6.4 Motor Temperature Thermal Protection............................................... 14
6.5 Digital Input......................................................................................... 15
6.6 Digital and Relay Output...................................................................... 16
7 Block Diagram of Main Functions........................................................ 17
7.1 Overview.............................................................................................. 17
7.2 Flow Command Processing.................................................................. 17
7.3 Pressure Command Processing........................................................... 19
7.4 Pressure Feedback Input..................................................................... 21
7.5 Quick Configuration For Rexroth HM20 Pressure Sensor.................... 22
7.6 Quick Configuration For Rexroth MOT-FC_HOY Motor ........................ 24
7.7 p/Q PID Control................................................................................... 26
7.8 Restore ASF Parameter........................................................................ 30
7.9 Extension Functions............................................................................. 31
7.9.1 Master / Slave Function....................................................................... 31
7.9.2 Sleep / Wake Function......................................................................... 33
7.9.3 Two Points / Double Pump Control..................................................... 35
7.9.4 Pressure Drop / Overshoot Compensation.......................................... 37
7.9.5 Pump Power Limitation....................................................................... 39
7.9.6 Hydraulic Soft Start and Separate Acceleration Ramp........................ 40
7.10 Protection Function............................................................................. 41
FcP 5020 Bosch Rexroth AG
Table of Contents
DOK-RCON03-FCP5020****-QU02-EN-P I

Page
7.10.1 Overview.............................................................................................. 41
7.10.2 Pressure Sensor Failure Detection....................................................... 41
7.10.3 Actual Pressure Monitoring.................................................................. 45
7.10.4 Oil Change Warning / Error Function................................................... 46
7.10.5 Pressure and Flow Command Limit..................................................... 47
7.10.6 Pump Thermal Protection.................................................................... 48
7.10.7 Sensor Monitoring............................................................................... 49
7.11 CytroPac Configuration....................................................................... 51
7.11.1 Overview.............................................................................................. 51
7.11.2 Load CytroPac Configuration............................................................... 51
7.11.3 CytroPac Sensor Monitoring ............................................................... 51
7.11.4 LED Flash Showing Converter Status.................................................. 52
8 FcP 5020 Parameter List...................................................................... 53
8.1 Terminology and Abbreviation in Parameter List................................. 53
8.2 Group F1: Quick Start Parameter........................................................ 54
8.3 Group F2: Input and Output Parameter............................................... 56
8.4 Group F3: p/Q PID Parameter.............................................................. 59
8.5 Group F4: System Protection and Pump Function Parameter............. 60
8.6 Auto-modified EFC Parameters in FcP Initialization............................ 62
8.7 Changed Setting Parameter by Load CytroPac Configuration............. 63
8.8 Monitoring Parameter.......................................................................... 65
9 Fieldbus Communication..................................................................... 66
9.1 Brief Introduction................................................................................ 66
9.2 Frequency Converter Parameter Address............................................ 66
10 Diagnosis............................................................................................. 69
10.1 Warning Code...................................................................................... 69
10.2 Error Code........................................................................................... 70
Index.................................................................................................... 71
Bosch Rexroth AG
Table of Contents
FcP 5020
II DOK-RCON03-FCP5020****-QU02-EN-P

1 Type Code
1.1 Frequency Converter Type Code Description
Fig. 1-1: EFC 5610 type code
This type code can be found on the Rexroth EFC converter.
FcP 5020 Bosch Rexroth AG
Type Code
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1.2 FcP 5020 ASF Type Code Description
Fig. 1-2: FcP 5020 ASF type code
FcP 5020 ASF software material number: R912006662
FcP 5020 ASF software type code: FWS-XFC01*-C10-01VRS-NN
ASF: Application Specific Firmware.
The ASF type code will not be printed and placed on the EFC converter, but only
a square adhesive label on the side, which represents important information
from ASF type code:
For example:
Fig. 1-3: ASF version information
Bosch Rexroth AG
Type Code
FcP 5020
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Parameter Name Value
F0.01 ASF version *
F0.02 ASF identifier 0x0C10
F0.03 ASF API required version *
F0.06 ASF evaluation time *
F0.07 ASF API version *
F0.10 ASF status
Bit0: ASF valid
Bit1: API compatible
Bit2: ASF certified
Bit3…Bit7: Reserved
Bit8: ASF evaluation period expired
Bit9: ASF invalid
Bit10: ASF API incompatible
Bit11: Reserved
Bit12: ASF runtime exceeded
Bit13: ASF stack overflow
Bit14…Bit15: Reserved
Tab. 1-1: FcP 5020 ASF basic information
* For accurate information, refer to the actual data provided on the product.
FcP 5020 Bosch Rexroth AG
Type Code
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2 Scope of Supply
If any item is found missing from standard supply package as listed below,
please contact Bosch Rexroth's local sales partner at your earliest convenience.
●Frequency Converter EFC 5610 with integrated Sytronix software
●Safety Instructions (available in multiple languages)
●EFC 5610 Quick Start Guide
●FcP 5020 ASF Quick Start Guide
3 Documentation Reference
Following documentations about the components could be found on Bosch
Rexroth homepage:
www.boschrexroth.com -> Products -> Electric Drives and Controls -> Product
Catalog -> CAD and documentation
Title Document
number
Document
type Catalog
Rexroth Frequency Converter EFC 3610 /
EFC 5610 Series R912005856 Quick Start Guide
Controller / Converter
Rexroth Frequency Converter EFC 3610 /
EFC 5610 Series R912005854 Operating Instruc- tions
Pressure transducer with integrated elec-
tronics-type HM20 30272 Data sheet Presssure Sensor
Rexroth IndraDyn E Standard Motors MOT-
FC for Frequency Converter Operation R911343624 Project Planning Manual Motor
Tab. 3-1: Documentation reference
Bosch Rexroth AG
Documentation Reference
FcP 5020
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4 Function Specification
FcP 5020 ASF is developed based on the EFC 5610 hardware platform to be
used for pressure and flow control. FcP 5020 has the functionality to automatic
switch between pressure and flow mode. The typical application is shown as be-
low.
This document only covers FcP 5020 relating functionalities. Please
review documentations in chapter 2 "Scope of Supply" on page 4
prior to applying power to EFC drive.
Control: Drive control
PACT: Pressure actual value
PCMD: Pressure command
QCMD: Flow command
Fig. 4-1: The diagram of typical application
FcP 5020 receives the pressure command generated by an external controller,
i.e. PLC or CNC, and the pressure feedback generated by the actual pressure
sensor mounted in the hydraulic system. By using both of the pressure com-
mand and the pressure feedback, the frequency converter is able to control the
motor speed automatically and in turn regulate the output flow of hydraulic
pump. The same mechanism is applicable to flow-based control mode to achieve
the same regulation purpose on the output flow of hydraulic pump.
The product provides the following features.
●Pressure / flow setting
– Easy command setting (internal commands, and 4 switchable parameters
for pressure command)
– Command setting possibility via analog or communication*
– Unique digital filtering for pressure command rising and dropping
– Preset standby mode (with minimum flow and pressure)
* External hardware for communication is required.
FcP 5020 Bosch Rexroth AG
Function Specification
DOK-RCON03-FCP5020****-QU02-EN-P 5/75

* Supported communication protocols: Profibus, CANopen, SercosIII, Multi-
Ethernet, Modbus.
●Pressure signal feedback
– Compatible with different types of pressure sensors (unlimited scaling for
the analog input signal)
– High resistance capability to electromagnetic interference (with the use of
high precision digital filter device for signal filtering)
– Quick configuration for Rexroth HM20 pressure sensor
●Quick configuration for Rexroth MOT-FC_HOY motor
●p/Q PID control
– p/Q control with automatic switching between pressure and flow control
modes
– Flow control
– Pressure control
– With 2 groups of switchable parameters provided
●Restore ASF parameter
●Extension functions
– Master / slave control
– Sleep / wake function
– Two points / double pump control
– Pressure drop / overshoot compensation
– Pump power limitation
– Hydraulic soft start and separate acceleration ramp
●Protection function
– Pressure sensor failure detection
– Actual pressure monitoring
– Oil change warning / error
– Pressure and flow command limit
– Pump thermal protection
– Sensor monitoring
●CytroPac configuration*
– Load CytroPac configuration
– CytroPac sensor monitoring
– LED flash showing converter status
* CytroPac is a specified compact Sytronix system with sensors. It applies
FcP 5020 application software.
Bosch Rexroth AG
Function Specification
FcP 5020
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5 Initial Start Up
After the electric hydraulic system has been correctly assembled, users can take
following steps for initial start up.
1. Select pressure sensor via F2.10 (for option ''0: Others", please set F2.06,
F2.07 manually).
2. Choose motor parameter via F1.15 and F1.16 for Rexroth MOT-FC_HOY mo-
tor. For other motors set F1.15 to 0, and set motor parameter in EFC pa-
rameter group C, please reference EFC 5610 quick start guide (material
number is R912005856).
3. Set pressure command via F1.03...F1.08 and flow command via F1.11,
F1.12.
4. Run the FcP system.
●The pressure command F1.05 and flow command F.12 default val-
ues are set to low values to prevent potential machine damage
caused by improper use during initial start up.
●For CytroPac application, set F1.20 according to different Cytro-
Pac type.
Code Name Setting range Default Min. Attri.
F1.03 Pressure command source
0: Depend on the value of
F1.04
1: Select by digital input (F1.04
shows status)
2: Analog input
3: Communication
0 - Stop
F1.04 Pressure command selection
0: Pressure command digital
setting 0
1: Pressure command digital
setting 1
2: Pressure command digital
setting 2
3: Pressure command digital
setting 3
0 - Run
F1.05 Pressure command digital set-
ting 0 0.0...1,000.0 bar 10.0 0.1 Run
F1.06 Pressure command digital set-
ting 1 0.0...1,000.0 bar 10.0 0.1 Run
F1.07 Pressure command digital set-
ting 2 0.0...1,000.0 bar 10.0 0.1 Run
FcP 5020 Bosch Rexroth AG
Initial Start Up
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Code Name Setting range Default Min. Attri.
F1.08 Pressure command digital set-
ting 3 0.0...1,000.0 bar 10.0 0.1 Run
F1.11 Flow command source
0: Depend on the value of
F1.12
1: Analog input (positive / nega-
tive)
2: Communication
0 - Stop
F1.12 Flow command digital setting 0...5,000 rpm 400 1 Run
F1.15 Motor type 0: Others
1: MOT-FC_HOY 1 - Stop
F1.16 Motor power level
0: No selection
1...5: Reserved
6: 1.5 kW
7: 2.2 kW
8: 3 kW
9: 4 kW
10: 5.5 kW
11: 7.5 kW
12: 11 kW
13: 15 kW
14: 18.5 kW
15: 22 kW
16: 30 kW
17: 37 kW
18: 45kW
19: 55 kW
20: 75 kW
21: 90 kW
0 - Stop
F1.20 CytroPac parameter initializa-
tion
0: No selection
1: CytroPac Basic
2: CytroPac Advanced
3: CytroPac Advanced + Comm.
0 - Stop
F2.06 Pressure feedback correspond-
ing to 10V or 20mA 0.1...1,000.0 bar 100.0 0.1 Stop
Bosch Rexroth AG
Initial Start Up
FcP 5020
8/75 DOK-RCON03-FCP5020****-QU02-EN-P

Code Name Setting range Default Min. Attri.
F2.07 Pressure feedback null offset in
V or mA 0.0...5.0 V, mA 4.0 (mA) 0.1 Stop
F2.10 Pressure sensor type
0: Others
1: HM20-2X/10-C
2: HM20-2X/50-C
3: HM20-2X/100-C
4: HM20-2X/160-C
5: HM20-2X/250-C
6: HM20-2X/315-C
7: HM20-2X/400-C
8: HM20-2X/630-C
9: Reserved
10: Reserved
11: HM20-2X/10-H
12: HM20-2X/50-H
13: HM20-2X/100-H
14: HM20-2X/160-H
15: HM20-2X/250-H
16: HM20-2X/315-H
17: HM20-2X/400-H
18: HM20-2X/630-H
3 - Stop
Tab. 5-1: Parameter list of initial start up
FcP 5020 Bosch Rexroth AG
Initial Start Up
DOK-RCON03-FCP5020****-QU02-EN-P 9/75

6 Electric Connection
6.1 Overview
Fig. 6-1: Wiring Diagram
●FcP 5020 I/O functionality is given higher priority over the stand-
ard EFC functions. The standard EFC functionality assigned to ter-
minal will be ignored and taken over by the ASF terminal assign-
ment (non-zero entries in ASF).
●For details about the wiring of temperature sensor as shown in
the diagram above, please refer to EFC 5610 operating instruc-
tions (material number is R912005854).
Bosch Rexroth AG
Electric Connection
FcP 5020
10/75 DOK-RCON03-FCP5020****-QU02-EN-P

6.2 Analog Input
This section shows how analog input can be configured. The following figure is
an example for analog input AI2, which has been assigned to pressure feedback.
The configuration for AI1 and EAI is similar to AI2, only with different parameters
shown in the table below.
Fig. 6-2: Example with analog input AI2 assigned to pressure feedback
Code Name Setting Range Default Min. Attri.
E1.35 AI1 input mode 0: 0...20 mA
1: 4...20 mA
2: 0...10 V
3: 0...5 V
4: 2...10 V
2 - Run
E1.40 AI2 input mode 1 - Run
H8.05 EAI input mode 0...4 (same as E1.35)
5: -10V...10V 0 - Stop
F2.00 Analog input AI1 0: No function assigned from ASF
1: Pressure command
2: Pressure feedback
3: Flow command
0 - Stop
F2.01 Analog input AI2 2 - Stop
F2.02 External analog input EAI
(-10V...10V, 4...20mA) 0 - Stop
F2.04 Pressure command corre-
sponding to 10V or 20mA 0.1...1,000.0 bar 10.0 0.1 Stop
F2.05 Pressure command null off-
set in V or mA 0.0...5.0 V, mA 0.0 0.1 Stop
FcP 5020 Bosch Rexroth AG
Electric Connection
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Code Name Setting Range Default Min. Attri.
F2.06 Pressure feedback corre-
sponding to 10V or 20mA 0.1...1,000.0 bar 100.0 0.1 Stop
F2.07 Pressure feedback null off-
set in V or mA 0.0...5.0 V, mA 4.0
(mA) 0.1 Stop
F2.08 Flow command correspond-
ing to 10V or 20mA 1...5,000 rpm 400 1 Stop
F2.09 Flow command null offset in
V or mA 0.0...5.0 V, mA 0.0 0.1 Stop
Tab. 6-1: Analog input parameter list
As the default FcP 5020 configuration, analog input AI2 [F2.01 = 2] is configured
as the pressure feedback input. Analog input AI1 or EAI1 has no preassigned
configuration by the FcP 5020.
For broken wire protection of analog input, please check the following table for
setting range of E1.61. For more information please refer to EFC 5610 converter
document (R912005856 or R912005854).
Code Name Setting Range Default Min. Attri.
E1.61 Broken wire protection
0: Inactive
1: Warning
2: Error
0 - Stop
Tab. 6-2: Parameter E1.61 for broken wire protection
Wire broken monitoring function for all analog inputs can be activa-
ted by E1.61. Default value of E1.61 has been set to 0 in FcP 5020
and 2 in CytroPac default setting.
Bosch Rexroth AG
Electric Connection
FcP 5020
12/75 DOK-RCON03-FCP5020****-QU02-EN-P

6.3 Analog Output
This section shows how analog output can be configured. The following figure is
an example for analog input AO1. The configuration for EAO is similar to AO1,
only with different parameters shown in the table below.
Fig. 6-3: Example with analog output AO1
Code Name Setting Range Default Min. Attri.
E2.25 AO1 output mode 0: 0...10 V
1: 0...20 mA 1 - Run
E2.27 AO1 gain setting 0.00...10.00 1.00 0.00 Run
F2.04 Pressure command corre-
sponding to 10V or 20mA 0.1...1,000.0 bar 10.0 0.1 Stop
F2.06 Pressure feedback corre-
sponding to 10V or 20mA 0.1...1,000.0 bar 100.0 0.1 Stop
F2.08 Flow command correspond-
ing to 10V or 20mA 1...5,000 rpm 400 1 Stop
F2.31 AO1 output
(use E2.27 for gain)
0: No function assigned from ASF
1: Pressure command (scaled by
F2.04)
2: Pressure feedback (scaled by
F2.06)
3: Setting speed (include direc-
tion) (scaled by F2.08)
4: Output speed (include direc-
tion) (scaled by F2.08)
0 - Run
F2.32 EAO output
(use H8.27 for gain) 0 - Run
FcP 5020 Bosch Rexroth AG
Electric Connection
DOK-RCON03-FCP5020****-QU02-EN-P 13/75

Code Name Setting Range Default Min. Attri.
H8.25 EAO output mode 0: 0...10 V
1: 0...20 mA 0 - Run
H8.27 EAO gain setting 0.00...10.00 1.00 0.01 Run
Tab. 6-3: Analog output parameter list
As the default configuration, FcP 5020 ASF does not set the AO1 output, i.e.
[F2.31] = 0. The AO1 output can be used by the EFC function.
6.4 Motor Temperature Thermal Protection
Both AI1 / EAI and AO1 / EAO can be used for motor thermal protection. For Sy-
tronix application with MOT-FC_HOY motor, the PTC connection is arranged by
using AO as current output and AI as voltage input, with the parameters being
pre-set for C1.72, C1.73, E1.40 and E2.25. Users need to connect PTC sensor
accordingly and set [E1.60] = 1, [E2.26] = 11 in order to activate this function.
For more details, please refer to chapter 12.10, motor protection of EFC 5610
operating instruction (R912005854 / edition 05).
Bosch Rexroth AG
Electric Connection
FcP 5020
14/75 DOK-RCON03-FCP5020****-QU02-EN-P

6.5 Digital Input
Code Name Setting Range Default Min. Attri.
F2.16 X1 input 0: No function assigned from ASF
1: Pressure command selection bit0
2: Pressure command selection bit1
3: p/Q parameter selection
4: Reserved
5: Master / slave mode switch
6: Oil filter warning
7: Oil level warning
8: Oil temperature warning
9: Oil filter error
10: Oil level error
11: Oil temperature error
12: Oil level / temperature error
13: Oil filter warning inverse
14: Oil level warning inverse
15: Oil filter error inverse
16: Oil level / temperature error inverse
17: Reserved
18: Reserved
19: Reserved
20: Pressure drop compensation trigger
21: Pressure overshoot compensation
trigger
0
(RUN) - Stop
F2.17 X2 input 0
(Error reset) - Stop
F2.18 X3 input 0 - Stop
F2.19 X4 input 0 - Stop
F2.20 X5 input 0 - Stop
F2.21 EX1 input 0 - Stop
F2.22 EX2 input 0 - Stop
F2.23 EX3 input 0 - Stop
F2.24 EX4 input 0 - Stop
Tab. 6-4: Digital input parameter list
The default setting of terminal X1...X5, EX1...EX4 in ASF is ''0''. This means no
function from ASF is assigned, only EFC firmware functions assigned are active.
Part of the EFC firmware parameters, including [E1.01] = 34 (X2 set to ''Reset''),
will be pre-set automatically in ASF.
The digital inputs F2.16…F2.24, are mutually exclusive, which therefore do not
allow for any identical setting (except 0) between the parameters, otherwise
warning APF1 will be triggered.
FcP 5020 Bosch Rexroth AG
Electric Connection
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Four pressure command parameters are available in ASF, and these can be
switched according to setting of F1.03 and DI or F1.04. The following table
shows the correspondence between p/Q parameter selection through DI and
F1.04, but DI switches pressure commands without changing F1.04.
Pressure command selection bit0 0 1 0 1
Pressure command selection bit1 0 0 1 1
F1.04 0 1 2 3
Pressure command F1.05 F1.06 F1.07 F1.08
Tab. 6-5: The setting of digital input selection (F1.04)
Two parameter sets for p/Q controller are available in ASF, and these can be
switched according to setting of F3.00 and DI or F3.01. The following table
shows the correspondence between p/Q parameter selection through DI and
F3.01, but DI switches parameter sets without changing F3.01.
p/Q parameter selection 0 1
F3.01 0 1
p/Q parameter F3.10...F3.19 F3.30...F3.39
Tab. 6-6: The setting of digital input selection (F3.01)
6.6 Digital and Relay Output
Code Name Setting Range Default Min. Attri.
F2.36 DO1 output 0: No function assigned from ASF
1: Converter warning
2: Green CytroPac flashing LED
3: Red CytroPac flashing LED
1 - Run
F2.37 EDO output 0 - Run
F2.40 Relay 1 output 0: No function assigned from ASF
1: Converter warning
2: Two points / double pump control
0 - Run
F2.41 Extension relay output 0 - Run
Tab. 6-7: Parameter list of digital and relay output
The FcP 5020 default setting of DO1 is ''1'', i.e. the frequency converter warning.
Meanwhile the default setting of relay and EDO when connected to ASF are both
''0'', which means the function of relay and EDO is assigned by EFC firmware.
The EFC parameter E2.15 has been set to ''14'' (frequency converter error) by
ASF as FcP default setting. For more EFC parameter changed as FcP default set-
ting, please refer to chapter 8.6 "Auto-modified EFC Parameters in FcP Initializa-
tion" on page 62.
Bosch Rexroth AG
Electric Connection
FcP 5020
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