Bosch SYEPS 1X Series User manual

Operating instructions
RE 30201-B/07.2014
Replaces: 11.2012
English
SYEPS series 1X
Highly dynamic electrohydraulic punching system for NC punching
machines

The data specified only serve to describe the
product. No statements concerning a certain
condition or suitability for a certain application
can be derived from our information. The
information given does not release the user
from the obligation of own judgment and
verification. It must be remembered that our
products are subject to a natural process of
wear and aging.
© This document, as well as the data,
specifications and other information set forth in
it, are the exclusive property of Bosch Rexroth.
It may not be reproduced or given to third
parties without its consent.
An example configuration is shown on the title
page. The delivered product may, therefore,
differ from the product which is pictured.
The original operating instructions were
created in the German language.

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Contents
Contents
1 About this documentation 6
1.1 Validity of the documentation 6
1.2 Required and supplementary documentation 6
1.3 Representation of information 7
1.3.1 Safety notes 7
1.3.2 Symbols 8
1.3.3 Terms 8
1.3.4 Abbreviations 9
2 Safety instructions 10
2.1 About this chapter 10
2.2 Intended use 10
2.3 Improper use 10
2.4 Personnel qualification 11
2.5 General safety instructions 11
2.6 Product-specific safety instructions 12
2.7 Personal protective equpment 15
2.8 Safety equipment 15
2.8.1 Safety function 15
3 General notes on damage to material and the product 17
4 Scope of delivery 18
4.1 High 18
4.2 Advanced 19
4.3 Standard 20
5 About this product 22
5.1 Performance description 22
5.1.1 Product description 22
5.1.2 Digital axis control HNC100 25
5.1.3 Functional description 28
5.2 Identification of the product 29
5.2.1 Type code of the SYEPS punching system
29
6 Transport and storage 30
6.1 Transporting the SYEHL punching axis 30
6.1.1 SYEHL punching axis 30
6.1.2 Transporting with lifting gear 30
6.1.3 Storing the SYEHL punching axis 31
6.1.4 Transporting and storing the HNC100 and electronics 32
7 Installation 33
7.1 Unpacking 34
7.2 Installation conditions 34
7.2.1 For the HNC100 34
7.2.2 For the SYEHL punching axis 34
7.3 Installation orientation and piping of SYEHL punching axes 35
7.3.1 General 36
7.4 Recommended accessories 36
7.5 Installing the SYEPS punching system 37

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7.5.1 Mounting the SYEHL punching axis mechanically 38
7.5.2 Mounting the SYEHL punching axis hydraulically 38
7.5.3 Installing the HNC100 43
7.5.4 Connecting the SYEHL and HNC100 electrically 43
7.5.5 Wiring of high-response valve 50
8 Commissioning 57
8.1 Initial commissioning 57
8.1.1 General operating conditions – control side, system 57
8.1.2 Commissioning the HNC100 and electronics 58
8.1.3 Inspecting piping and wiring 65
8.1.4 Charging the accumulator 65
8.1.5 Mounting the flushing valve 68
8.1.6 Connecting the pressure gauge 68
8.1.7 Commissioning the power unit 69
8.1.8 Setting high pressure (HP) and low pressure (LP) 69
8.1.9 Referencing the axis 70
8.1.10 Checking the actual position values and max. stroke 70
8.1.11 Checking the position control 71
8.1.12 Flushing the hydraulic system 71
8.1.13 Removing the flushing valve and mounting the original pilot valve 72
8.1.14 Adjusting the zero point of the high-response valve 73
8.1.15 Testing the machine functions 74
9 Operation 81
9.1 Switch-on sequence 81
9.1.1 Boot mode 83
9.2 Operating modes 84
9.2.1 Punching operating modes 84
9.2.2 Forming operating modes 84
9.2.3 Operating mode in the event of a fault 84
9.2.4 Changing the operating mode 84
9.2.5 Coordinate system of the SYEPS punching system 85
9.2.6 Reference position 85
9.2.7 Punching operating modes 85
9.2.8 Forming operating modes 89
9.2.9 Failsafe operation 92
9.2.10 Energy-saving mode 93
9.3 Configuration 94
9.3.1 Machine data 94
9.3.2 R parameters 97
9.3.3 Process variables 101
9.3.4 Measurement 103
9.3.5 Data transmission 105
9.4 HNC100 error messages - error handling 108
10 Maintenance and repair 110
10.1 Cleaning and care 110
10.2 Maintenance and inspection schedule 110

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10.2.1 Inspection for leakage 111
10.2.2 Check for generation of noise 111
10.2.3 Check of mounting elements 111
10.2.4 Check of operating temperature 111
10.2.5 Check of gas charge pressure 111
10.2.6 Oil analysis 112
10.2.7 Open-loop-controlled operation of the punching axis with test box VT-VET in
conjunction with variant “High“ 113
10.3 Repair 113
10.4 Spare parts 114
11 Demounting and replacement 116
11.1 Required tools 116
11.2 Preparing demounting 116
11.3 Demounting 116
11.4 Preparing the components for storage or further use 116
11.5 Replacing components 116
11.5.1 Pilot valve STW243 (High), STW365 (Advanced); H-4WEH (Standard) 117
11.5.2 High-response valve High STW243/STW282 117
11.5.3 High-response valve Advanced STW365 118
11.5.4 High-response valve H-4WEH 10 118
11.5.5 LP accumulator 119
11.5.6 HP accumulator 119
11.5.7 Position measuring system 119
12 Disposal 121
12.1 Environmental protection 121
13 Extension and conversion 121
14 Troubleshooting 122
14.1 How to proceed for troubleshooting 122
14.2 Oil cleanliness 122
14.3 Fault table 123
15 Technical data 126
16 Annex 127
16.1 Address directory 127
17 Alphabetical index 128

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Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014
1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the following SYEPS products of series 1X:
•SYEPS-1X/0600...
•SYEPS-1X/0750...
•SYEPS-1X/0900...
•.SYEPS-1X/1200...
This documentation is intended for fitters, operators, service technicians and plant
operators.
This documentation contains important information on the safe and appropriate
installation, transport, commissioning, maintenance, operation, removal and simple
troubleshooting of the SYEPS punching system of series 1X.
▶ Read this documentation thoroughly, especially Chapter 2 “Safety instructions“
one page 10, before working with the product.
1.2 Required and supplementary documentation
▶ Only commission the product when you have the documents identified with the
book symbol at hand and have understood and observed them. You can find
operating instructions and data sheets on our website www.boschrexroth.com
under “Documentation and Downloads“
Table 1: Required and supplementary documentation
Title Document no. Document type
Punching, cutting, forming - standardized, optimal Drive & Control
solutions
08101-02 Product information
System documentation of the plant manufacturer General information on the
complete system
Order confirmation Contains the pre-set technical data
of your SYEPS punching system
Installation drawing with spare parts items Drawing
Hydraulic and electrical circuit diagram Drawing
Punching axis for punching machines 30200 Data sheet
Digital axis control, type VT-HNC100...3X 30139-B Operating instructions
Digital axis control, type VT-HNC100...3X 30139 Data sheet
Declaration on environmental compatibility in the fields of EMC, climate
and mechanical stress, type VT-HNC100...3X
30139-U Declaration on environmental
compliance
Online help for commissioning software WIN-PED® 6 or WIN-PED® 7 Available on the Internet at www.
boschrexroth.com/hnc100
“First Steps“ with WIN-PED®
General product information on hydraulic products 07008 Product information
Hydraulic valves for industrial applications 07600-B Operating instructions
Hydraulic fluids based on mineral oils and related hydrocarbons 90220 Data sheet
General operating instructions for hydraulic power units and hydraulic
assemblies
07009-B Operating instructions
2/2 directional seat valve, direct operated, with solenoid actuation, type
KSDE
18136-20 Data sheet

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Title Document no. Document type
4/3, 4/2 and 3/2 directional valve with wet-pin AC or DC solenoids, type
WE
23178 Data sheet
Smoothly switching 4/2 and 4/3 directional valve with DC solenoids, type
WE…73…A12
23183 Data sheet
3/2, 4/2 and 4/3 directional valves, internally pilot operated, externally
pilot operated, types 4WEH and 4WH (high-response valve for standard
axis)
24751 Data sheet
Pressure relief valve, direct operated, type DBD 25402 Data sheet
2- and 3-way high-response cartridge valve, type .WRCE.../S (basic data
sheet for STW243)
29136 Data sheet
Card holder type VT 3002 29928 Data sheet
Electrical amplifier, type VT-VRRA1 30045 Data sheet
Booster amplifier, type VT-MSFA1 30260 Data sheet
Booster amplifier, type VT-MSFA1 30260-B Operating instructions
Analog amplifier module, type VT-MSPA1-30 30224 Data sheet
Pressure transducer for hydraulic applications, type HM 20 30270 Data sheet
Pressure transducer for hydraulic applications, type HM 20 30270-MON Installation instructions
Diaphragm-type accumulator, type HAD 50150 Data sheet
Diaphragm-type accumulator, type HAD2,0-350 50161-B Operating instructions
Bladder-type accumulator, type HAB 50170 Data sheet
Bladder-type accumulator, typeHAB..-4X 50170-B Operating instructions
Mating connectors and cable sets for valves and sensors 08006 Data sheet
Service case with test device 29685 Data sheet
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, these are explained in the following sections.
1.3.1 Safety notes
This documentation contains safety notes in Chapter 2.6 “Product-specific safety
instructions“ and Chapter 3 “General notes on damage to material and the product“
as well as before a sequence of activities or instructions for action, which involve the
risk of personal injury or damage to equipment. The measures described for averting
the hazard must be observed.
Safety notes are structured as follows:
SIGNAL WORD
Type and source of hazard!
Consequences in the case of non-observance
▶ Measures to avert the hazard
▶ <List>
•Warning symbol: draws attention to a hazard
•Signal word: identifies the degree of hazard

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Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014
•Type and source of hazard!: 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
Table 2: Hazard classes according to ANSI Z535.6-2006
Warning sign, signal word Meaning
DANGER Indicates a hazardous situation which, if not avoided, will
certainly result in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE Damage to property: The product or the environment can be
damaged.
1.3.2 Symbols
The following symbols refer to notes, which are not relevant to safety, but increase
the legibility of the documentation.
Table 3: Meaning of symbols
Symbol Meaning
If this information is disregarded, the product cannot be used or operated
in an optimum manner.
▶ Individual, independent step of action
1.
2.
3.
Numbered instructions for action:
The numbers indicate that the activities are to be carried out consecutively.
1.3.3 Terms
The following terms are used in this documentation:
Table 4: Terms
Term Meaning
ER command value Pump command value
HNC100 Digital axis control for electrohydraulic punching axes for High and
Advanced: SYHNC100-NIB-1-3X/... for Standard: VT-HNC100-1-3X/...
RE xxxxx Rexroth document in English language
SYEHL Punching axis consisting of control block and cylinder
SYEPS Electrohydraulic punching system
Precharge pressure Gas charge pressure p0 of the hydraulic accumulator
WIN-PED® Operator software WIN-PED® 6 or WIN-PED® 7 for the HNC100
WIN-PED project Data directory in which the software data of the HNC100 are saved
WinView Program for visualizing recorded variables in conjunction with WIN-PED®

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1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Table 5: Abbreviations
Abbreviation Meaning
EMC Electromagnetic compatibility
FC Frequency converter
GND Ground
HP High pressure
HF High frequency
HNC Hydraulics-capable Numerical Control
LP Low pressure
NEC National Electrical Code
NEMA National Electrical Manufacturers Association
NRG Negative Ramp Gradient
p Pressure (symbol)
PPower
PE Protective Earth
pact Actual pressure value
POP Position over Plate
PRG Positive Ramp Gradient
pcomm Pressure command value
PSP Position Softpunch
PTE Position Tool Exchange
PUP Position under Plate
SYEPS Electrohydraulic Punch System
UBSupply voltage
US Undervoltage
VDE Verband der Elektrotechnik, Elektronik und Informationstechnik (Association
for electrical, electronic and information technologies)
WIN-PED® Windows Programming, Editing and Diagnosis software for the HNC100

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2 Safety instructions
2.1 About this chapter
The product has been manufactured according to the generally accepted rules of
current technology. There is, however, still a risk of personal injury or damage to
equipment if you do not observe this Chapter and the safety instructions contained
in this documentation.
▶ Read these instructions completely and thoroughly before working with the
product.
▶ Keep this documentation in a location where it is accessible to all users at all
times.
▶ Always pass the product together with the required documentation to third
parties.
2.2 Intended use
The SYEPS punching system is an electrohydraulic system component.
You may use the product as follows:
•for controlling the punching strokes of NC punching machines in different
operating modes.
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“.
2.3 Improper use
Any use other than described in the section “Intended use” is considered as
improper and is therefore not permitted.
For damage resulting from improper use, Bosch Rexroth AG will not bear liability.
The risks arising from improper use lie exclusively with the user.
If unsuitable products are installed or used in safety-relevant applications,
unintended operational states may occur in the application that can cause
personal injury and/or damage to property. For this reason, use a product only in
safety-relevant applications, if this use is expressly specified and permitted in the
documentation of the product. For example, in explosion-protection areas or in
safety-related parts of a control (functional safety).
The product is used improperly:
•If you do not adhere to the technical data, operating conditions and performance
limits specified in the data sheet and given in the order confirmation
•If you do not observe national EMC regulations during operation for the application
at hand. Notes on an EMC-compliant installation can be found in the EMC test
documentation of Bosch Rexroth, if required. The manufacturer of the system or
machine is responsible for complying with the limit values stipulated in national
regulations (European countries: EC Directive 2004/108/EC (EMC Directive); USA:
See National Electrical Code (NEC), National Electrical Manufacturers Association
(NEMA) as well as regional engineering regulations.