Bosch rexroth Sytronix SvP 7030 IMC User manual

Sytronix SvP 7030 IMC
Variable-speed pump drive
Operating Manual
RE 62312-B,
03.2022

Schutzvermerk
© Bosch Rexroth AG ©2022
Alle Rechte vorbehalten, auch bezüglich jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe
sowie für den Fall von Schutzrechtsanmeldungen.
Verbindlichkeit
Die angegebenen Daten dienen allein der Produktbeschreibung und sind nicht als zugesicherte Eigenschaften im
Rechtssinne zu verstehen. Änderungen im Inhalt der Dokumentation und Liefermöglichkeiten der Produkte sind
vorbehalten.
ec8c67c28e5c85900a347e885f45b0ce, 1, en_US

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Table of contents
1 About this documentation 7
1.1 Validity of the documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Required and supplementary documentation. . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Representation of information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.2 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.3 Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.4 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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 and technology-related safety instructions. . . . . . . . . . . . . . . . . . . . . 13
2.7 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Obligations of the machine end-user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 General notes on damage to property and damage to the product 19
4 Scope of delivery 21
5 Product description 23
5.1 Performance description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Device description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Overview of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Single-axis converter XCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.2 Panel XDP1 (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3.3 Motor-pump group MPA02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.4 Pressure transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Identification of the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.1 Plates on the drive controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.2 Nameplate of the motor pump group MPA02. . . . . . . . . . . . . . . . . . . . 32
5.5 Acceptance tests and approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5.1 UL/CSA certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6 Customer testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Transport and storage 35
6.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Transporting the Sytronix system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.1 Handling the motor-pump unit with cranes or similar lifting gear. . . . 36
6.2.2 Weight of motor-pump units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.2.3 Ambient conditions for transporting . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.3 Storing Sytronix systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.1 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.2 Storage times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Installation 40
7.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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7.3 Mechanical installation of the motor-pump unit. . . . . . . . . . . . . . . . . . . . . . . . 40
7.3.1 Installation conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.3.2 Compatibility with foreign substances . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3.3 Installation position and orientation of the motor-pump unit. . . . . . . 41
7.3.4 Connecting SvP 7030 hydraulically. . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4 Mounting the machine control cabinet components. . . . . . . . . . . . . . . . . . . . . 50
7.4.1 Control cabinet design and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.4.2 Single-axis converter XCS*-W0023. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.4.3 Single-axis converter XCS*-W0054. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.4.4 Single-axis converter XCS*-W0070. . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4.5 Single-axis converter XCS*-W0100. . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4.6 Single-axis converter XCS*-W0120. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.4.7 Single-axis converter XCS*-W0150. . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.4.8 Single-axis converter XCS*-W0180. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.4.9 Single-axis converter XCS*-W0210. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.4.10 Single-axis converter XCS*-W0250. . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.4.11 Single-axis converter XCS*-W0280. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.4.12 Braking resistor HLR01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.4.13 Additional components mains filters XNF and power choke XNL. . . . 73
7.5 Connecting the Sytronix system SvP 7030 electrically. . . . . . . . . . . . . . . . . . . 74
7.5.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.5.2 Input and output assignment at drive controller ctrlX DRIVE. . . . . . . 75
7.5.3 Mains connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.5.4 Control voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.5.5 Specification of the digital/analog inputs/outputs. . . . . . . . . . . . . . . 83
7.5.6 Overall connection diagram XCS*-W0023. . . . . . . . . . . . . . . . . . . . . . 87
7.5.7 Overall connection diagram XCS*-W0054/W0070. . . . . . . . . . . . . . . . 88
7.5.8 Overall connection diagram XCS*-W01xx. . . . . . . . . . . . . . . . . . . . . . 89
7.5.9 Overall connection diagram XCS*-W02xx. . . . . . . . . . . . . . . . . . . . . . 90
7.5.10 Electrical data of single-axis converter XCS*-W0023 . . . . . . . . . . . . . 91
7.5.11 Electrical data of single-axis converter XCS*-W0054. . . . . . . . . . . . . . 93
7.5.12 Electrical data of single-axis converter XCS*-W0070. . . . . . . . . . . . . . 95
7.5.13 Electrical data of single-axis converter XCS*-W0100. . . . . . . . . . . . . . 97
7.5.14 Electrical data of single-axis converter XCS*-W0120. . . . . . . . . . . . . . 99
7.5.15 Electrical data of single-axis converter XCS*-W0150 . . . . . . . . . . . . . 101
7.5.16 Electrical data of single-axis converter XCS*-W0180 . . . . . . . . . . . . . 103
7.5.17 Electrical data of single-axis converter XCS*-W0210 . . . . . . . . . . . . . 105
7.5.18 Electrical data of single-axis converter XCS*-W0250 . . . . . . . . . . . . . 107
7.5.19 Required electric strength of connected cables . . . . . . . . . . . . . . . . . 108
7.5.20 Connection points power section/control section . . . . . . . . . . . . . . . 109
7.5.21 XCS, connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.5.22 Connection points of control section. . . . . . . . . . . . . . . . . . . . . . . . . 113
7.5.23 On-board connection points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.5.24 Connection points of the components. . . . . . . . . . . . . . . . . . . . . . . . 119

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RE 62312-B,
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8 Commissioning 155
8.1 Initial commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8.1.1 Filling the Sytronix system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.1.2 Commissioning of the pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.1.3 Commissioning of the drive controller. . . . . . . . . . . . . . . . . . . . . . . . . 157
8.2 Recommissioning after standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9 Operation 159
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.2 Operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.3 Error mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.4 LED PF01 (device state) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.5 Sercos/EtherCAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.5.1 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.5.2 Port LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
9.5.3 Diagnostic LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10 Maintenance and repair 165
10.1 Cleaning and care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.2 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.3.1 Motor-pump unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.3.2 Drive controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.4 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.5 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
11 Decommissioning 167
12 Demounting and replacement 169
12.1 Required tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
12.2 Preparing demounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
12.3 Demounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
12.4 Preparing the components for storage or further use. . . . . . . . . . . . . . . . . . . . 169
13 Environmental protection and disposal 171
13.1 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
13.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14 Troubleshooting 173
14.1 How to proceed for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
14.2 Error/diagnostic message memory in the drive controller ctrlX DRIVE. . . . . . . 173
14.3 Errors and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
14.4 Fault table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
15 Service and support 177
16 Index 179

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RE 62312-B,
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Sytronix SvP 7030 IMC
Required and supplementary documentation
Bosch Rexroth AG
RE 62312-B,
03.2022
1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the following Sytronix systems:
●SvP 7030 IMC
This documentation is intended for engineers, fitters, operators, service techni-
cians and plant operators.
This documentation contains important information on the safe and proper
mounting, transport, commissioning, operation, use, maintenance, demounting
and simple troubleshooting of the Sytronix system SvP 7030 IMC.
●Read this documentation thoroughly, especially Chapter 2 “Safety instruc-
tions“ and Chapter 3 “General notes on damage to property and damage to
the product“, before working with the Sytronix system.
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 under-
stood and observed it.
Table 1: Required and supplementary documentation
Title Document no. Document type
System
Sytronix SvP 7030 IMC, variable-speed pump drives RE 62312-FK Functional
description
ctrlX DRIVE
ctrlX DRIVE Drive Systems R911386579 Project Planning
Manual
ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX
DRIVE
R911383774 Application
Manual
Security Manual Electric Drives and Controls (IT
Security)
R911342562 Project Planning
Manual
ctrlX DRIVE Runtime AXS-V03 Functions R911410073 Application
Manual
ctrlX DRIVE, Diagnostic Messages of Runtime AXS-
V03RS
R911409763 Reference Book
ctrlX DRIVE, Parameters of Runtime AXS-V-03RD R911409808 Reference Book
Motors
Rexroth Sytronix SvP 70xx Motor-Pump Unit MPA02 R911387041 Operating
instructions
MS2N Synchronous Servomotors R911347583 Project Planning
Manual
Pumps
Internal gear pump, type PGH.-3X RE 10227 Data sheet
Internal gear pump, type PGH.-3X RE 10227-B Operating
instructions
Internal gear pump PGM series 4X RE 10235 Data sheet
Internal gear pump PGM series 4X RE 10235-B Operating
instructions
Axial piston units for variable-speed drives A10FZO,
A10VZO, A10FZG and A10VZG
RE 91485 Data sheet
Axial piston units for variable-speed drives A10FZO,
A10VZO, A10FZG and A10VZG series 10
RE 91485-01-B Operating
instructions

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Sytronix SvP 7030 IMC
Representation of information
Bosch Rexroth AG
RE 62312-B,
03.2022
Title Document no. Document type
Miscellaneous
Rexroth Sytronix Mounting and Commissioning Axial
Piston Variable Pump - A10VZO/A10VSO/A4VSO
R911341629 Mounting instruc-
tions
Control Cabinet: Air Conditioning, EMC, Design, IP
Code, Electrics, IndraDrive, Rexroth EFC/Fv, Sytronix
R911344988 Project Planning
Manual
Rexroth Connection Cables IndraDrive and IndraDyn R911322949 Selection data
Pressure transducer for hydraulic applications, type
HM20
RE 20372 Data sheet
Pressure transducer for hydraulic applications, type
HM20
RE 20272-B Operating
instructions
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.
1.3.1 Safety instructions
In this documentation, safety instructions are contained in chapter 2 and
chapter 3 and wherever sequences of actions or instructions are explained
which bear the risk of personal injury or damage to property. The hazard avoid-
ance measures 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 or source of the hazard
●Consequences:describes the consequences in the case of non-observance
●Precautions:states, how the hazard can be avoided
Hazard classifications according to ANSI Z535.6-2011
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.
1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but
increase the comprehensibility of the documentation.
If this information is disregarded, the product cannot be used or operated in an
optimum manner.
●Individual, independent action
Numbered instruction: The numbers indicate that the actions must be
carried out one after the other.

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Sytronix SvP 7030 IMC
Representation of information
Bosch Rexroth AG
RE 62312-B,
03.2022
1.3.3 Designations
The following terms are used in this documentation:
Table 2: Designations
Designation Meaning
Drive controller Device. The drive controller basically consists of the
power section and the control section
AXS Firmware for drive controllers
A10FZO Axial piston pump, fixed displacement
HM20 Pressure transducer
IndraWorks Ds Bosch Rexroth software tool for drive commissioning
MPA02 Motor-pump unit consisting of internal gear pump and
MS2N motor
MS2N Servo motor
PGH/PGM Internal gear pump, fixed displacement
SvP system Servo-variable pump system
Sytronix Variable-speed pump drives
XCS Single-axis converter
1.3.4 Abbreviations
The following terms are used in this documentation:
Table 3: Abbreviations
Designation Meaning
CPU Central Processing Unit (processor)
EMC ElectroMagnetic Compatibility
ESD ElectroStatic Discharge
IMC Injection Molding Control
n Speed
p Pressure
Q Flow
RE Rexroth document in English language
TF Technology Function
Vg Displacement
PE Protective Earth
SW Software
VAC Volts of Alternating Current (AC voltage)
VDC Volts direct current (DC voltage)

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Representation of information
Bosch Rexroth AG
RE 62312-B,
03.2022

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Sytronix SvP 7030 IMC
Improper use
Bosch Rexroth AG
RE 62312-B,
03.2022
2 Safety instructions
2.1 About this chapter
The Sytronix system is designed and manufactured according to the generally
accepted code of practice. However, there is still a risk of personal injury and
damage to property if you do not observe this chapter and the safety instruc-
tions in this documentation.
●Read this documentation completely and thoroughly before working with the
Sytronix system.
●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 product on
to third parties.
2.2 Intended use
This product is an electro-hydrostatic drive system. You may use the product as
follows:
●For controlling a flow with alternating pressure control functionality (p/Q
control).
●As a pure high-precision hydraulic pressure supply.
The Sytronix system is intended exclusively for being integrated in a machine or
installation or for being assembled with other components to form a machine
or system. The product may be commissioned only if it is integrated in the
machine/system for which it is designed.
Make sure that components supplied by the customer, e.g. electric drives, are
sufficiently dimensioned.
Observe the technical data, operating conditions and performance limits
according to the data sheet and the order confirmation.
The product is intended exclusively for professional use and not for private
usage.
Operation according to the intended use also implies that you have read
and understood this documentation completely, especially chapter 2 “Safety
instructions“.
No plausibility checks and no checks of actual values (pressure and speed) are
provided in the Sytronix system.
Make sure that the plausibility check is executed in the machine control.
For application-specific adjustment of the parameters within the framework of
initial commissioning, please get in touch with your technical contact at Bosch
Rexroth.
2.3 Improper use
Any use other than described in the section “Intended use” is considered as
improper and is therefore not permitted.
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. Therefore, please
only use a product for safety-relevant applications if this use is expressly speci-
fied and permitted in the documentation of the product. For example, in explo-
sion-protection areas or in safety-related parts of a control (functional safety).
Bosch Rexroth AG does not assume any liability for damage caused by improper
use. The user assumes all risks involved with improper use. Improper use of the
product includes:

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●If you do not adhere to the technical data, operating conditions and per-
formance limits specified in the data sheet and given in the order confirma-
tion.
●If you do not observe national EMC regulations during operation for the
application at hand. The manufacturer of the system or machine is respon-
sible for complying with the limit values stipulated in national regulations
(European countries: EU Directive 2014/30/EU (EMC Directive); USA: See
National Electrical Code (NEC), National Electrical Manufacturers Associa-
tion (NEMA) as well as regional engineering regulations.
●If you use the Sytronix system SvP 7030 with a conventional MS2N motor in
a potentially explosive atmosphere.
2.4 Qualification of personnel
The activities described in this documentation require basic knowledge of
mechanics, electrics and hydraulics as well as knowledge of the appropriate
technical terms. In order to ensure safe use, these activities may only be car-
ried out by an expert in the respective field or an instructed person under the
direction and supervision of an expert.
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 per-
taining to the work to be undertaken. An expert must observe the relevant
specific professional rules and have the necessary expert knowledge. Expert
knowledge means for example:
●The ability to read and completely understand electrical and hydraulic circuit
diagrams,
●Having knowledge of the wiring of electrical components, in particular, com-
pletely understanding the correlations regarding safety equipment and
●Knowledge of the function and structure of hydraulic components as well as
of their installation and connection,
●Basic knowledge of open and closed-loop control technology and the ability
to parameterize application software
Bosch Rexroth offers training courses that support your qualification in spe-
cific 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 pro-
tection.
●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 accessory and spare parts released by the manufacturer in order to
rule out personnel hazards arising from unsuitable spare parts.
●Comply with the technical data and ambient conditions specified in the
product documentation.

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●If unsuitable products are installed or used in safety-relevant applications,
unintended operational states can occur in these applications, which can
cause personal injury and damage to property. Therefore, please only use a
product for safety-relevant applications if this use is expressly specified and
permitted in the documentation of the product.
●You may commission the product only when it has been established that
the final product (for example, a machine or system), in which the Rexroth
product is installed, complies with national regulations, safety regulations
and standards relevant for the application.
2.6 Product and technology-related safety instructions
WARNING System parts under pressure and ejecting hydraulic
fluid!
When working on hydraulic systems with stored energy
(e.g. accumulators) hydraulic components may still be
under pressure even after the pressure supply was
switched off. During installation and demounting, com-
ponents or parts may be hurled around and cause per-
sonal injuries and/or damage to property. There is more-
over the risk of serious injury caused by a powerful,
ejecting hydraulic fluid jet.
−Before working on the hydraulic product ensure that
the hydraulic system is depressurized and the elec-
trical control de-energized.
−Completely depressurize machines and systems
before working on hydraulic products.
WARNING Non-compliance with functional safety!
Hydraulic components control movements in machines
or systems. In the event of mechanical and electrical
faults, e.g. power supply failure due to lightning or fluc-
tuations in the power supply, the machine can start up
unexpectedly and perform uncontrolled movements and
thus cause personal injuries.
−When setting up your circuit, observe functional
safety, e.g. according to EN ISO 13849.
−If necessary, fit light barriers or safety guards for pro-
tection against dangerous movements.
−Observe the notes in the project planning manual and
in the data sheet with regard to protection and appli-
cation.
−If an accumulator is provided, install a check valve
and an accumulator safety block.

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WARNING Sytronix system falling down!
Sytronix systems are heavy. When improperly handled,
they can fall down and cause severe injuries and
crushing, because the parts can be, for example, sharp-
edged, heavy, oily, loose or bulky.
−Transport the Sytronix system using suitable lifting
gear at the points provided for this purpose.
−Ensure a stable position during transport to the place
of installation.
−Wear personal protective equipment when handling
the Sytronix system.
−Comply with the national laws and regulations
regarding occupational health and safety for trans-
porting/handling.
WARNING Electromagnetic interference!
Frequency converters can be disturbed by interference
emitted by the machine. This can cause malfunction,
which can lead to severe injuries.
−Use only devices, connecting elements and electrical
control cables that comply with the EMC Directive.
−If required, install shielding elements.
−Keep a sufficient distance to sources of radiated dis-
turbance.
−Observe the EMC limit values and notes on EMC for
the electrical components of the Sytronix system.
WARNING Electromagnetic radiated interference!
Electrical components of the Sytronix assemblies may
emit electromagnetic interference. This can cause mal-
function, which can lead to severe injuries.
−Keep a sufficient distance to sources of radiated dis-
turbance.
−If required, install shielding elements.
−Observe the EMC limit values and notes on EMC for
the electrical components of the Sytronix system.
WARNING Improper mounting!
Mounting of hydraulic components using mounting
screws of reduced strength, improper mounting or
mounting with insufficient stability may cause the
hydraulic components to become loose and fall down.
Consequently, hydraulic fluid may leak and lead to
personal injuries and/or damage to property. Heavy
hydraulic components may cause bruises or fatal injury.
−Completely mount hydraulic components according
to the mounting specifications using suitable
mounting aids.
−Mount the Sytronix system at places that are suitable
to bear the weight of the system.
−Observe the specified mounting and installation
notes and observe the given tightening torques and
bolt strengths.
−Check fixing devices regularly during operation.

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WARNING Unexpected machine movements!
Working on running systems poses a danger to life
and limb. The work steps described in these operating
instructions may only be performed on shut down sys-
tems. Before beginning work:
−Make sure that the drive motor cannot be switched
on.
−Make sure that all force-transmitting components and
connections (electrical, pneumatic, hydraulic) are
switched off according to the manufacturer’s instruc-
tions and are secured against restarting. If possible,
remove the main fuse of the system.
−Make sure that the system is completely depres-
surized. Please follow the system manufacturer’s
instructions.
−Only qualified personnel are authorized to install the
Sytronix system.
WARNING Lines under pressure!
Risk of injury by catapulted components or plug screws
due to breakage of the weakest system component (e.g.
due to missing pressure relief feature).
−Do not exceed the maximum operating pressure!
−Limit the pressure in the system by means of over-
pressure elements.
−Test the system at test pressure according to ISO
4413.
−Never disconnect, open or cut pressurized lines!
−Before carrying out any installation or other work,
depressurize the Sytronix system.
WARNING High electrical voltage!
Danger to life and risk of injury caused by electric shock!
−The Sytronix system may only be connected by or
under the supervision of a skilled electrician.
−Switch off the power supply before all maintenance,
repair or installation work and secure it against
restarting.
−Before starting installation work, plugging and
unplugging connectors, and carrying out any work,
switch the Sytronix system off. Secure the electrical
equipment against restarting.
−Before switching the control system on, check the
protective conductor on all electrical devices for
proper connection according to the wiring diagram.
WARNING Fire and explosion!
In conjunction with heat sources, leaking hydraulic fluid
can result in fire or explosion.
−Inspect the Sytronix assemblies for leakage.
−Keep sources of heat and fire away from hydraulic oil
and ensure sufficient ventilation.

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WARNING Penetrating water and humidity!
In case of use in humid or wet environments, water or
humidity may penetrate at electrical plug-in connectors
or hydraulic components. This case may lead to malfunc-
tion of the pump and to unexpected movements in the
system which may result in personal injury and damage
to property.
−Only use the Sytronix system 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.
WARNING Dewing!
If the device temperature is lower than the ambient tem-
perature, dewing may occur, which can lead to malfunc-
tion and thus to a risk of injury.
−Comply with the technical data and ambient condi-
tions specified in the product documentation.
−Set cooling units with set temperature to the max-
imum shop floor temperature, not lower!
−Set cooling units with adjusting temperature setting
so that the temperature inside the control cabinet
is not lower than the ambient temperature. Set the
temperature limitation to the maximum shop floor
temperature!
−Use exclusively well sealed control cabinets to rule
out dewing caused by incoming warm and humid
ambient air.
−If control cabinets are operated with the doors open
(commissioning, repairs, etc.), make sure that after
the doors were closed, the drive controllers can at no
time be cooler than the air in the control cabinet. For
this reason, provide for sufficient circulation in the
control cabinet.
−Observe functional safety according to EN ISO
13849.
WARNING Health-damaging hydraulic fluid!
Risk of intoxication and injury! Contact with hydraulic
fluids causes damage to health (e.g. eye injuries, skin
damage, poisoning by inhalation and swallowing).
−Always check the lines for wear and damage before
any commissioning.
−Wear protective gloves, goggles and suitable work
clothing.
−If nevertheless hydraulic fluid comes into contact
with the eyes or penetrates the skin, consult a doctor
immediately.
−When handling hydraulic fluids, strictly observe the
safety notes of the hydraulic fluid manufacturer.

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WARNING Hot oil!
Risk of burning by hot oil that may escape during serv-
icing.
−Avoid contact with an ejecting oil jet.
−Shut the system down and replace or have damaged
components replaced.
WARNING Electromagnetic and magnetic fields!
People with active medical implants (e.g. heart pace-
makers), passive metallic implants (e.g. hip prosthesis)
and pregnant women might possibly risk hazards by elec-
tromagnetic or magnetic fields in the immediate vicinity
of components of the electric drive and control system
and the associated current-carrying conductors.
Areas in which components of the electric drive and con-
trol system and associated current-carrying conductors
are mounted, commissioned and operated may be dan-
gerous to those people.
−Before entering these areas, the above-mentioned
persons should seek advice from their physician.
−Observe the occupational safety and health regula-
tions applicable at the site of operation, for installa-
tions equipped with components of the electric drive
and control system and the associated current-car-
rying conductors.
CAUTION Formation of smoke!
Risk of breathing difficulties due to the formation of
smoke caused by overloading of the electric drive motor
during longer operation of the Sytronix system with
excessively large flows and at excessive pressure!
−Provide motor protection (e.g. overload protection,
circuit breaker).
CAUTION Hot surfaces!
Risk of burning. The Sytronix system heats up during
operation.
−Let the Sytronix system cool down before touching it.
−Protect yourself by wearing heat-resistant protective
clothing, e.g. gloves.
CAUTION High noise emission during operation!
The noise emission of Sytronix systems depends, among
others, on speed, operating pressure and the installation
situation. In the case of an unfavorable arrangement
and connection of pumps with attached components in
a system, noise and hydraulic fluid noise may be gener-
ated.
−Wear hearing protection during operation.
−An excessive sound pressure level may indicate mal-
function.

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CAUTION Rough, slippery surface!
Hydraulic oil escaping through leaky fittings and screwed
connections causes a risk of slipping.
−Check fittings and screwed connections for tight-
ness/leakage.
−If necessary, retighten fittings/screws and remove
escaped oil immediately.
CAUTION Vibration!
Possible generation of noise and consequently fatigue
as well as interference with speech communication or
disturbance of acoustic signals.
−Where appropriate, take decoupling measures such
as the installation of anti-vibration dampers and use
flexible hoses.
CAUTION Missing equipotential bonding!
Electrostatic charging of the pump due to flowing media,
an incorrect earthing concept or missing equipotential
bonding may lead to malfunctions or uncontrolled move-
ments at the machine and thus cause injuries.
−Provide for correct earthing and provide for proper
equipotential bonding.
2.7 Personal protective equipment
Personal protective equipment for users of the product consists of:
●Protective gloves and safety shoes for transporting the Sytronix system
●Hearing protection for working in the direct vicinity of the running Sytronix
system
2.8 Obligations of the machine end-user
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. Unless otherwise documented, Bosch Rexroth
products are designed for operation in local, physically and logically secured
networks with access restrictions for authorized persons, and they are not
classified according to IEC 62443-4-2.
Further information can be found in the Security Manual R911342562.

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3 General notes on damage to property and
damage to the product
The warranty only applies to the delivered configuration.
The warranty becomes void if the product is incorrectly mounted, commis-
sioned or operated, not used as intended and/or handled improperly.
NOTICE Inadmissible mechanical load!
Impact or shock forces on the Sytronix system and
attached components may damage or even destroy it.
−Do not hit on the drive shaft of the unit.
−Never use the Sytronix system as a handle or step. Do
not place/put any objects on top of it.
NOTICE Foreign particles and dirt in the Sytronix system!
Risk of damage, wear and malfunctions due to ingress of
dirt and foreign particles.
−During installation, ensure utmost cleanliness in
order to prevent foreign particles such as welding
beads or metal chips from getting into the hydraulic
lines.
−Before commissioning, make sure that all hydraulic
connections are tight and that all seals and
closing elements of plug-in connections are correctly
installed and not damaged.
−When filling the system with hydraulic fluid, filter
the fluid with a suitable filtering system to minimize
contamination with solid particles and water in the
system.
−Do not use cotton waste or linty cloths for cleaning.
−Take care that no cleaning agents enter the hydraulic
system.
NOTICE Wear!
Wear may lead to malfunctions.
−Carry out the prescribed maintenance work at the
time intervals specified in the operating instructions.
NOTICE Environmentally harmful hydraulic fluid!
Leaking hydraulic fluid leads to environmental pollution.
−Immediately remedy any leakage.
−Dispose of the hydraulic fluid in accordance with the
national regulations in your country.
NOTICE Insufficient pressure!
If the pressure falls below the specified value, damage
can occur or the product be destroyed.
−Make sure that the pressure cannot fall under the
prescribed minimum value.

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NOTICE Insufficient hydraulic fluid!
If you commission or operate the Sytronix system
without or with insufficient hydraulic fluid, the control
system is immediately damaged or even destroyed.
−When commissioning or re-commissioning a machine
or system, make certain that the housing chamber as
well as the suction and working lines of the Sytronix
system are filled with hydraulic fluid and remain filled
during operation.
NOTICE Corrosion due to water and saltwater!
Contact with salt water leads to increased corrosion.
Thus, mounting screws and plug screws as well as move-
able components may be chemically corroded and dam-
aged and thus cause leakage and oil getting into the envi-
ronment.
−So take suitable corrosion protection measures, e.g.
by means of an anti-corrosion coating.