Bosch rexroth VT-SVTSY-1 User manual

Operating instructions
RE 29681-B/11.2019 English
Service case with test device
for servo valves without
integrated electronics
Type VT-SVTSY-1
HAD6100_99

The data specified only serve to describe
the product. If information on the use of the
product is given, it is only to be regarded as
application examples and recommendations.
Catalog information does not constitute
warranted properties. The information given
does not release the user from the obligation
of own judgment and verification. 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 AG. It may not be reproduced or given
to third parties without its consent.
The cover shows an example configuration.
The product supplied may differ from the
solution shown here.
The original operating instructions were
prepared in German.

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3/28Content
Content
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and supplementary documentation 5
1.3 Representation of information 5
2 Safety instructions 7
2.1 About this chapter 7
2.2 Intended use 7
2.3 Improper use 7
2.4 Qualification of personnel 8
2.5 General safety instructions 8
2.6 Product-specific safety instructions 9
2.7 Safety equipment 12
2.8 Personal protective equipment 12
3 General information on damage to property anddamage to the product 13
4 Scope of delivery 14
5 About this product 15
5.1 Performance description 15
5.2 Product description 15
5.3 Block diagram/pinout 16
5.4 Device view 17
5.5 Overview of servo valves suitable for being tested 18
5.6 Identification of the product 18
6 Transport and storage 19
7 Installation 19
7.1 Unpacking 19
7.2 Installation conditions 19
7.3 Required tools 20
7.4 Recommended accessories 20
7.5 Before use 20
7.6 Place of use 20
7.7 Installing the test device for servo valve without integrated electronics 20
8 Commissioning 22
8.1 Initial commissioning 22
9 Operation 22
10 Maintenance and repair 23
10.1 Cleaning and care 23
10.2 Repair 23
10.3 Spare parts 23
11 Demounting and replacement 24
11.1 Required tools 24
11.2 Preparing demounting 24
11.3 Preparations for storage and further use 24
12 Disposal 25
12.1 Environmental protection 25
12.2 Return to Bosch Rexroth AG 25
12.3 Packaging 25

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12.4 Materials used 25
12.5 Recycling 25
13 Extension and modification 26
14 Troubleshooting 26
14.1 How to proceed for troubleshooting 26
15 Technical data 26
16 Annex 27
16.1 List of addresses 27

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1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the test case
VT-SVTSY-1-1X/1-1-1-1-1/(PRUEFG.+KOFFER), Mat. no. R900962017
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, operation, use, maintenance, and removal
of the product.
▶ Read this documentation thoroughly and in particular chapter 2 “Safety
instructions“ and chapter 3 “General information on damage to property
anddamage to the product“, before working with the product.
1.2 Required and supplementary documentation
▶ Only commission the product, when you have the data sheet marked with
the book symbol at hand and when you have read and understood the
documentation of the valve that you wish to test or commission. A list of the
valves that can be tested by means of the test device can be found in chapter
5.5 “Overview of servo valves suitable for being tested“ on page 18.
▶ Bosch Rexroth data sheets are available online at
www.boschrexroth.com/mediadirectory
Table 1: Required and supplementary documentation
1.3 Representation of information
In order to allow you to work directly and safely with the test device described,
standardized safety notes, symbols, terms and abbreviations are used in this
documentation. For a better understanding, they are explained in the following
sections.
1.3.1 Safety instructions
In this documentation, safety instructions are included in chapter2.6 “Product-
specific safety instructions“ and in chapter3 “General information on damage
to property anddamage to the product“ and whenever sequences of actions or
instructions are explained which bear the risk of personal injury or damage to
property. The described hazard avoidance measures must always be observed.
Safety instructions are structured as follows:
Title Document number Document type
Service case with test device for servo valves without integrated electronics,
type VT-SVTSY-1-1
29681 Data sheet

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SIGNAL WORD
Type and source of danger!
Consequences in case of non-compliance
▶ Hazard avoidance measures
▶ <Enumeration>
•Warning symbol: draws attention to a hazard
•Signal word: identifies the degree of hazard
•Type and source of danger: Specifies the type and source of danger
•Consequences: describes the consequences in case of non-observance
•Precaution: specifies how the hazardous situation can be prevented
Table 2: Hazard Classifications according to ANSI Z535.6-2011
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 could
be damaged.
1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase
the comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
If this information is disregarded, the product cannot be used or operated
in an optimum manner.
▶ Individual, independent action
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be carried out one after the
other.
1.3.3 Designations
The following terms are used in this documentation:
Table 4: Designations
Designation Meaning
Test device Device included in the scope of delivery for testing valves
RE xxxxx Rexroth document in English language
1.3.4 Abbreviations
The following abbreviations are used in this documentation:

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Table 5: Abbreviations
Abbreviation Meaning
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage
2 Safety instructions
2.1 About this chapter
The test device described in the following has been manufactured according to
good engineering practice. However, there is still a risk of personal injury and/or
damage to property if you do not observe this chapter and the safety instructions
in this documentation.
▶ Read this documentation 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 include the required documentation when you pass the service case
with the test device on to third parties.
2.2 Intended use
The test device is suitable for activating and functional testing of Bosch Rexroth
servo valves without integrated electronics.
The technical data of the device have to be observed without exception, and the
specified ambient conditions have to be adhered to, see RE 29681.
The use in potentially explosive atmospheres is not permitted.
The device is provided for temporary use in a controlled electromagnetic
environment (according to EN 61326-1, table 3, testing according to EN 61326-
2-1) on hydraulic industrial equipment for commissioning, analyzing, testing and
servicing of hydraulic valves in plant.
Dry and clean ambient conditions have to be ensured.
2.3 Improper use
Any use deviating from the intended use is improper and thus not admissible.
Improper use voids any warranty claims. It is also regarded as improper use if the
test device is operated outside the indicated performance limits and operating
conditions, especially the prescribed ambient conditions.
The test device is not provided for use in Class B environments (domestic/
residential). Should the test device nevertheless be used in a domestic/residential,
controlled electromagnetic environment (emission limit values of class B), further
measures have to be taken to prevent electromagnetic interference.
Bosch Rexroth AG does not assume any liability for damage caused by improper
use. The user assumes all risks involved with improper use.

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2.4 Qualification of personnel
The activities described in this documentation require basic knowledge of
electrical installation, control technology, programming and hydraulics as well
as knowledge of the appropriate technical terms. In order to ensure safe use,
these activities may only be carried 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 pertaining
to the work to be undertaken. An expert must observe the relevant specific
professional rules and have the necessary hydraulic expert knowledge.
Expert knowledge means, amongst others:
• the ability to read and completely understand circuit diagrams,
• in particular, completely understanding the correlations regarding safety
equipment and
• knowledge of the function and structure of hydraulic components,
• knowledge of the function and structure of electrical systems and components.
When working with the test device on a system/machine, it is advantageous if
the work is carried out by a specialist who is familiar with the system!
It is assumed that the device is used by trained and professional personnel in a
controlled electromagnetic environment to ensure proper usage.
Bosch Rexroth offers training courses that support your qualification in specific
fields. You can find an overview of training contents on the Internet at: http://
www.boschrexroth.com
2.5 General safety instructions
• Observe the valid regulations on accident prevention and environmental
protection.
• 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 genuine Rexroth accessories and spare parts in order to exclude any
hazard to persons due to unsuitable spare parts.
• Comply with the technical data and ambient conditions specified in the product
documentation.
• 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.
• Do not commission the product until you can be sure that the end product (for
example a machine/system) where the Rexroth products are installed comply

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with the country-specific provisions, safety regulations and standards of the
application.
• Please observe the safety-relevant information and risk specifications in the
operating instructions of the manufacturer of the connected hydraulic system
before commissioning the control with a hydraulic system.
• Please observe the general installation and safety regulations when working on
electrical systems.
• The information given in the product documentation with regard to the
use of the supplied components represents only application examples and
recommendations. The user has to check the suitability of the supplied device
and the information given in this documentation with regard to its use self-
dependently for his individual application as well as the compliance with the
safety regulations and standards valid for his application, and carry out the
required measures, changes and amendments.
• Technical data as well as connection and installation conditions are available in
the product documentation and have to be imperatively observed.
• In case of faults impairing the safety and changes in the operating behavior,
shut down the test device immediately and report the faults to the responsible
personnel.
• Generally, you must not modify or convert the product.
2.6 Product-specific safety instructions
WARNING
No functional safety!
Valves control movements in machines or systems. In the case of mechanical and
electrical faults, e.g. failure of the power supply, persons may get caught, hurled
or crushed by the installation.
▶ When using the test device in a system/machine make sure that it will not
make the functional safety of the system/machine ineffective or affect it in
whatever way!
Non-observance of control signals on the system side!
If control-side safety precautions are provided, they will be rendered ineffective.
▶ The test device may be used exclusively by personnel who are familiar with the
device, the valve and the hydraulic system. No liability is accepted for damage
caused by operating errors.

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WARNING
Hazardous movements!
It is not allowed for persons to stay within the range of motion of the machines,
in which the test device is to be used. The following are examples of possible
measures against unintended access of persons:
• Protective fences
• Protective grids
• Protective covers
• Warning signs, barrier tapes
▶ If persons have to enter the hazard zone while the control is active, provide
superordinate monitoring functions on the system side or measures for
personal safety. These measures must be provided according to the specific
data of the system and on the basis of the risk and error analysis of the system
manufacturer/user. In this connection, the safety provisions applied for the
system must be taken into account.
▶ In case of faults impairing the safety and changes in the operating behavior,
shut down the test device and the valve immediately and report the faults to
the responsible personnel.
System parts under pressure and ejecting hydraulic fluid!
When working on hydraulic systems with stored pressure energy (accumulator
or cylinders working under gravity), valves may even be pressurized after the
pressure supply has been switched off. During installation and demounting, the
valves or parts may be hurled around and cause personal injuries and/or damage
to property. There is moreover the risk of serious injury caused by a powerful,
ejecting hydraulic fluid jet.
▶ Before installing the test device in the hydraulic system, ensure that the
hydraulic system is depressurized and the electrical control de-energized.
▶ Completely depressurize machines and systems before working on hydraulic
products.
Improper mounting or placement!
The test device is a mobile device, which is not provided for firm installation in
the system/machine. While being used, the device is connected to the measuring
line and is placed loosely in/on the system.
▶ Place the device so that it cannot fall down.
▶ Place the device so that no one can step on it.
▶ Make sure that the measuring line does not pose a risk of stumbling for third
parties or the operator himself/herself.

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WARNING
High electrical voltage by incorrect connection!
Danger to life, risk of injury by electric shock!
▶ The test device may only be connected by or under the supervision of a
specialized electrician.
▶ Switch off the power supply before any work, during which the test device is
installed in the system, and secure it against restarting.
▶ Provide for proper, safe PE connection.
▶ Provide the supply voltage according to VDE0100 part 410.
▶ For the external voltage supply, it must be ensured that, even in the event of
a fault, the voltage limits defined for the test device are not exceeded. PELV
power supply units according to EN 60204, section 6.4.2 comply with these
requirements.
▶ Only connect voltages and power circuits that feature safe isolation from
dangerous voltages. Safe isolation can be achieved with isolation transformers,
safe optocouplers or mains-free battery operation, for example.
▶ Use exclusively the cables and leads contained in the test case for
interconnecting the test device in the valve control cable.
Missing equipotential bonding!
Electrostatic processes, an incorrect earthing concept or missing equipotential
bonding may lead to malfunctions or uncontrolled movements at the machine and
thus cause injuries.
▶ Provide for correct earthing and provide for proper equipotential bonding
when you connect the device in the machine.
Penetrating water and humidity!
In case of use in humid or wet environments, water or humidity may penetrate
at electrical plug-in connectors or the valve electronics. This case may lead to
malfunctions at the test device and to unexpected movements in the hydraulic
system which may result in personal injury and damage to property.
▶ Only use the test device 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.
CAUTION
Exceedance of the maximum temperatures!
Use of the test device outside the intended temperatures may lead to functional
failures. In the worst case, this may result in unexpected system movements and
thus constitute a risk of injury.
▶ Only use the test device within the ambient temperatures provided for it.

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CAUTION
Corrosion!
If the test device is used in humid environments or water, the test device and the
sockets may corrode. Mounting screws, sockets and jacks may lose their function
or their stability, respectively. This may lead to malfunction and cause a risk of
injury.
▶ Do not use the test device with corroded jacks and sockets.
Generally, avoid contact with salt water and salt-laden atmospheres!
2.7 Safety equipment
WARNING
Hazardous movements!
Danger to life, risk of injury or damage to property!
▶ Only the valves listed in these operating instructions may be operated with
this test device.
2.8 Personal protective equipment
Check determined personal protective equipment for completeness and protective
effect and wear it (observe customer regulations and list of personal protective
equipment).

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3 General information on damage to
property anddamage to the product
NOTICE
Impermissible mechanical loading!
Impact or shock forces on the test device may damage or even destroy it.
▶ Do not place/put any objects on top of it.
▶ Place the test device at locations, where it cannot fall down.
Malfunction and deformations!
Hydraulic components may reach high temperatures during operation. If the test
device heats up excessively when in contact with hot surfaces, malfunctions may
occur and the plastic housing of the test device may deform.
▶ Do not place the test device on or directly next to hot surfaces or places in or
on the system.
Dirt and foreign particles in hydraulic components!
Penetrating dirt and foreign particles lead to wear and malfunctions. Reliable
operation is thus no longer ensured.
▶ During installation, ensure utmost cleanliness in order to prevent foreign
particles such as welding beads or metal chips from getting into the electrical
connections (connectors, sockets, etc.).
▶ Do not use linty cloth for cleaning.
▶ Take care that no cleaning agents enter the housing.
Environmentally harmful electronic components!
Various integral components can lead to environmental pollution.
▶ Dispose of defective components in accordance with the currently applicable
national provisions in your country.
Uncontrolled disconnection and connection of plug-in connectors!
Device might be destroyed!
▶ Before carrying out any installation work, disconnect the device from the
mains or from the voltage source or de-energize it reliably.
▶ Do not plug in or pull electrical plug-in connectors as long as the voltage
supply is activated.
The warranty only applies to the delivered configuration.
The warranty becomes void if the product is incorrectly mounted, commissioned or
operated, not used as intended and/or handled improperly.

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4 Scope of delivery
The scope of delivery includes:
Service case with:
• Test device type VT-SVT-1-1X/, Mat no. R900214710
• Power supply unit type VT-SVTNT-2-2X/G12, Mat. no. R901510080
The power plug fits into power outlets in Germany and many European countries.
• Connection cables with mating connector Z31, type VT-SVTK-1-1X, Mat. no.
R900939983
• Connection cables with mating connector Z17, type VT-SVTK-2-1X, Mat. no.
R900939984
• Connection cables with mating connector Z8, type VT-SVTK-3-1X, Mat. no.
R900939985
In some countries, a country-specific adapter has to be used. It is not part of the
scope of supply.
▶ Check the scope of delivery for completeness.
▶ Check the scope of delivery for possible transport damage, see chapter 6
“Transport and storage”.
In case of complaints, please contact Bosch Rexroth AG, see chapter 16.1 “List
of addresses”.

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5 About this product
5.1 Performance description
The test device is suitable for commissioning and servicing work on hydraulic
systems employing servo-valves without integrated electronics. In the case of
machine malfunction it allows functions to be tested and faults to be localized
without having to demount the servo valves.
The test device can optionally be operated with the power supply unit included in
the scope of supply or a 9-Volt battery (not included in the scope of supply).
5.2 Product description
5.2.5 Functional description
To test the valve, proceed as follows:
1. Switch hydraulics off
2. Ensure power supply:
For mains operation:
Connect connection cable of the mains adapter to jack [6] of the test device.
When the adapter is plugged in, the battery is switched off as power supply.
For battery operation:
Insert a 9-V battery [11]!
3. Set the slide switch [1] to “ON“ → LED “power“ [8] is lit.
4. In case of battery operation, run battery test:
- Set selector switch [3] to “50 mA“
- Turn command value potentiometer [4] to “-100 %“
- Actuate pushbutton [2] for the battery test
→The display of the test device shows the battery charge level in %.
5. Select the type of coil of the valve by means of selector switch [3] on the test
device. See chapter 5.4, table 8.
6. Connect the test device (socket [7]) with the servo valve using the suitable
valve connection cable (the valve connection cables are wired so that both coils
of the solenoid are connected in series).
7. Turn command value potentiometer [4] to the central position until the display
shows 0 %!
8. Switch the hydraulic system on.
9. Turn command value potentiometer [4] slowly counter-clockwise or clockwise;
observe the movement of the motor or cylinder while doing so. If the servo-
valve works properly, the motor or cylinder thus activated can be sensitively
moved to the desired direction or position.

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5.3 Block diagram/pinout
Fig. 1: Block diagram
Table 6: Legend
4
9
6
10
1 mA
5 mA
7.5 mA
20 mA
30 mA
50 mA
1
5
3
11
2
7
A
C
B
D
8
u
i
AC adapter
VT-SVTNT-2-2X/G12
Servo valve
1 Power switch 2 Pushbutton for battery test 3 Selector switch for coil type
4 Command value potentiometer 5 Display of coil current 6 Socket for mains adapter cable
(with changeover switch)
7 Socket for valve connection
cable
8 “power“ LED 9 Voltage controller
10 Output stage 11 9-V battery

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5.4 Device view
Fig. 2: Indicator and control elements of the test device
Table 7: Assignment of coil data to valve types
Coil data Valve type
5 mA/500 mΩ per coil
7.5 mA/200 Ω per coil
20 mA/80 Ω per coil
30 mA/40 Ω per coil
50 mA/28 Ω per coil
4WS2E.10-4X 1)
4WS2E.10-4X 1)
4DS1EO2-1X 1)
3DS2EH10-2X 1)
30 mA/85 Ω per coil 4WS2EM6-1X/...
4WS2EM10-5X/...
30 MA/100 Ω per coil
50 mA/80 Ω per coil 4WS2EM6-1X
50 mA/85 Ω per coil 4WS2EM6-2X
1) Valves not available for new applications
1 Power switch
2 Pushbutton for battery test
3 Selector switch for coil type
4 Command value potentiometer
5 Display of coil current (in %)
6 Socket for mains adapter cable
7 Socket for valve connection cable
8 LED “power” indicator lamps
4
0 V
max. Current
OFF ON
– 100 %+
100 %
Command
12 V
1 mA
5
mA
7,5
mA 20 mA
30
mA
50
mA
–+
1
2
3
5
67
8

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5.5 Overview of servo valves suitable for being tested
At the time of publication of these operating instructions, test device VT-SVT-1 is
suitable for testing the following Rexroth servo valves:
Table 8: Suitable servo valves
Valve type Electrical connection Type connection cable
4WS2EM6-1X
4WS2EM6-2X K17 VT-SVTK-2-1X
4WS2EM10-5X K31 VT-SVTK-1-1X
4WS2EM10-4X 1)
4WS2EB10-4X 1)
4WS2EM10A-4X 1)
4WS2EB10A-4X 1)
4WS2EM16-2X
4DS1E02-1X 1)
3DS2EH10-2X 1)
K8 VT-SVTK-3-1X
1) Valves not available for new applications
5.6 Identification of the product
5.6.6 Information on the nameplate of the test device
The meaning of the information on the nameplate of the test device is explained in
the correspondingly numbered fields of the following table.
Fig. 3: Nameplate of test device
1 Word mark 2 Bosch Rexroth QR code
3 CE mark 4 Manufacturer's factory number
5 Date of manufacture 6 Designation of origin
7 Pin / socket pinout 8 Serial number
9 Material number 10 Material short text
12
3
4
5
6
7
10
9
8

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6 Transport and storage
There are no special transport instructions for this product. However, always
observe chapter 2 “Safety instructions“ and comply with the ambient conditions
specified in the data sheet for storage and transport.
Bosch Rexroth recommends keeping and transporting the test device and the
accessories in the case included in the scope of supply.
7 Installation
NOTICE
Condensed water!
Risk of short-circuit
▶ Allow the test device to acclimatize for several hours to prevent formation of
condensed water in the housing of the test device.
Penetrating humidity!
The housing of the test device is enclosed. Nevertheless, according to the
applicable ingress protection class, fluids may enter and lead to faults and short-
circuit. This will result in the fact that safe operation of the test device can no
longer be ensured.
▶ When working with the test device, always ensure that no fluids can enter the
electronics housing.
Major potential differences!
Risk of destroying the electronics by connecting or disconnecting plug-in
connectors under voltage.
▶ Switch off the power supply to the relevant system part before assembling the
device or when connecting and disconnecting connectors.
7.1 Unpacking
Dispose of the packaging in accordance with the national regulations of your
country.
7.2 Installation conditions
▶ For installing the product always observe the environmental conditions
specified in the technical data sheet.
NOTICE: The environment must be free from aggressive substances (acids, bases,
corrosive agents, salts, metal vapors, etc.) which may enter the device despite
compliance with the relevant protection class.
▶ Before commissioning, make sure that all the seals and plugs of the plug-in
connections are correctly installed to ensure that they are leak-proof and no
fluids or foreign particles can enter the product.

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7.3 Required tools
No special tools are required for the installation.
7.4 Recommended accessories
The accessories required for operating the test device is contained in the case set.
7.5 Before use
▶ Before using the test device, check compliance of the type designation on the
nameplate with your order or job order number.
7.6 Place of use
The test device should not be installed next to power electronics (e.g. frequency
converters, etc.)
7.7 Installing the test device for servo valve without integrated
electronics
7.7.7 Installing the test device mechanically
CAUTION
Insufficient installation space!
Insufficient space may lead to jamming or abrasions in case of actuation and
adjustment work on the valve.
▶ Ensure sufficient space.
▶ Make sure that actuation and adjustment elements and plug-in connectors are
easily accessible.
Sharp edges!
Sharp edges may be present at the place of installation of the valve to be tested.
These may result in cutting or abrasive injuries during transport or mounting/
demounting.
▶ Wear the required personal protective equipment as required according to the
place of use.
NOTICE
Faulty installation of plug-in connectors and cables!
Improperly mounted connectors and measuring lines and cables may loosen and
result in incorrect measurements.
▶ Only start with testing when you made sure that all connections are properly
connected.