REXROTH Sytronix DRn 5020 User manual

Frequency-Controlled Pump
Drive System
Sytronix DRn 5020
Operating Instructions
R912004808
Edition 05

Frequency-Controlled Pump Drive System
Sytronix DRn 5020
Operating Instructions
DOK-SYTROX-DRN5020****-IT05-EN-P
RS-6f471f3f0d70c0330a347ea5015b1c95-5-en-US-4
Copyright © Bosch Rexroth (Xi'an) Electric Drives and Controls Co., Ltd. 2018
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial prop‐
erty rights.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
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Bosch Rexroth AG DOK-SYTROX-DRN5020****-IT05-EN-P
Frequency-Controlled Pump Drive System Sytronix DRn 5020

Table of Contents
Page
1 About this Documentation.............................................................................................. 7
1.1 Validity of the Documentation................................................................................................................. 7
1.2 Required and Amending Documentation................................................................................................ 8
1.3 Representation of Information................................................................................................................ 9
1.3.1 Consistency......................................................................................................................................... 9
1.3.2 Safety Instructions............................................................................................................................... 9
1.3.3 Symbols............................................................................................................................................. 10
1.3.4 Abbreviations..................................................................................................................................... 10
2 Safety Instructions....................................................................................................... 11
2.1 General Information on 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-dependent Safety Instructions..................................................................... 13
2.7 Obligations of the Machine End-user.................................................................................................... 15
3 Safety Instructions for Electric Drives and Controls..................................................... 16
3.1 Definitions of Terms.............................................................................................................................. 16
3.2 General Information.............................................................................................................................. 18
3.2.1 Using the Safety Instructions and Passing them on to Others.......................................................... 18
3.2.2 Requirements for Safe Use............................................................................................................... 18
3.2.3 Hazards by Improper Use.................................................................................................................. 19
3.3 Instructions with Regard to Specific Dangers....................................................................................... 20
3.3.1 Protection against Contact with Electrical Parts and Housings......................................................... 20
3.3.2 Protective Extra-low Voltage as Protection against Electric Shock .................................................. 21
3.3.3 Protection against Dangerous Movements........................................................................................ 22
3.3.4 Protection against Electromagnetic and Magnetic Fields during Operation and Mounting............... 23
3.3.5 Protection against Contact with Hot Parts......................................................................................... 24
3.3.6 Protection during Handling and Mounting......................................................................................... 24
3.3.7 Battery Safety.................................................................................................................................... 25
3.3.8 Protection against Pressurized Systems........................................................................................... 25
3.3.9 General Warnings of Damage to Property and Damage to the Product........................................... 26
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 28
4 About This Product...................................................................................................... 29
4.1 Frequency Converter Type Code Description...................................................................................... 29
4.2 DRn 5020 ASF Type Code Description................................................................................................ 30
4.3 Scope of Delivery.................................................................................................................................. 30
4.4 Product Description.............................................................................................................................. 31
4.5 Component Overview........................................................................................................................... 32
4.5.1 System Components......................................................................................................................... 32
DOK-SYTROX-DRN5020****-IT05-EN-P Bosch Rexroth AG I/143
Frequency-Controlled Pump Drive System Sytronix DRn 5020
Table of Contents

Page
4.5.2 Installation of DRn System in a Cabinet............................................................................................ 34
4.6 Function Specification........................................................................................................................... 35
4.7 Input and Output Allocation at the Frequency Converter...................................................................... 37
4.7.1 Standard Wiring Diagram.................................................................................................................. 37
4.7.2 Control Terminals Description........................................................................................................... 38
Digital inputs................................................................................................................................... 38
Analog inputs.................................................................................................................................. 38
Digital outputs................................................................................................................................. 39
4.7.3 Power Terminal................................................................................................................................. 39
4.7.4 Control Terminals.............................................................................................................................. 40
Control terminals figure.................................................................................................................. 40
4.8 Product Identification............................................................................................................................ 41
5 Transport and Storage................................................................................................. 42
5.1 Drive Controllers................................................................................................................................... 42
5.2 Pressure Sensor................................................................................................................................... 42
6 Assembly and Installation............................................................................................ 43
6.1 General Information.............................................................................................................................. 43
6.2 Unpacking............................................................................................................................................. 43
6.3 Installation Conditions........................................................................................................................... 43
6.3.1 Installation Conditions for Motor Pump Unit...................................................................................... 43
6.3.2 Installation Conditions for Frequency Converter and Additional Components.................................. 44
6.4 Assembling the DRn System................................................................................................................ 45
6.4.1 Mechanically Connecting the Motor Pump Unit................................................................................. 45
6.4.2 Hydraulically Connecting the Motor Pump Unit................................................................................. 45
6.4.3 Connection Technique....................................................................................................................... 46
General Notes................................................................................................................................ 46
Power Connection.......................................................................................................................... 48
Connect the Motor Fan................................................................................................................... 52
6.4.4 Connection EFC 5610 for DRn 5020................................................................................................. 53
Digital input NPN / PNP wiring....................................................................................................... 53
Digital output DO1a, DO1b load pull-up / pull-down wiring............................................................ 54
Relay output terminals.................................................................................................................... 54
6.4.5 Connection of the Pressure Transducer............................................................................................ 56
6.4.6 Electronic Component Assembly and Installation in Control Cabinet................................................ 57
7 Commissioning of Sytronix DRn 5020 System............................................................ 58
7.1 Introduction and Basics........................................................................................................................ 58
7.1.1 Application type................................................................................................................................. 58
7.1.2 Overview of User Interface................................................................................................................ 59
Overview of DRn5020 IndraWorks Dialog...................................................................................... 59
Sub-dialog Communication............................................................................................................ 64
Sub-dialog Command Values......................................................................................................... 64
Sub-dialog Speed Adaptation......................................................................................................... 65
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Frequency-Controlled Pump Drive System Sytronix DRn 5020
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Page
Sub-dialog Pressure Feedback...................................................................................................... 66
Sub-dialog Motor Control and Parameters..................................................................................... 67
Sub-dialog System Configuration................................................................................................... 67
7.1.3 Main Functions.................................................................................................................................. 68
Load Pump Parameters.................................................................................................................. 68
Speed Adaption.............................................................................................................................. 72
Pressure Command Learning......................................................................................................... 74
Boost Function................................................................................................................................ 76
Motor Derating................................................................................................................................ 78
Speed Masking............................................................................................................................... 80
Auxiliary Pump................................................................................................................................ 82
Motor Stall and Large Leakage Detection...................................................................................... 83
Configuration of Pressure Sensor.................................................................................................. 84
Load Motor Parameter.................................................................................................................... 86
Restore ASF Parameter................................................................................................................. 87
LED Flash Showing Converter Status............................................................................................ 88
Oil Change Warning / Error Function............................................................................................. 89
Sleep / Wake-up Function.............................................................................................................. 90
Threshold for Oil Level / Oil Temperature...................................................................................... 91
7.2 Getting started with DRn 5020.............................................................................................................. 92
7.2.1 Notes on Commissioning................................................................................................................... 92
7.2.2 Hydraulic System Preparation........................................................................................................... 93
7.2.3 Electric Hardware Connection Preparation....................................................................................... 93
7.2.4 Operating Preparation....................................................................................................................... 94
7.2.5 Relevant Parameters......................................................................................................................... 95
7.2.6 Converter I/O Configuration............................................................................................................... 97
Analog Input AI1............................................................................................................................. 97
Analog Input AI2............................................................................................................................. 98
Extended Analog Input EAI............................................................................................................ 99
Analog Output AO1...................................................................................................................... 100
Digital Input................................................................................................................................... 100
Digital and Relay Output............................................................................................................... 101
7.2.7 First Commissioning........................................................................................................................ 102
7.3 Commissioning (advanced)................................................................................................................ 103
7.3.1 Parameter Setting............................................................................................................................ 103
Overview and introduction............................................................................................................ 103
7.4 DRn Soft Start..................................................................................................................................... 107
7.5 Parameter Functions.......................................................................................................................... 107
7.5.1 Terminology and Abbreviation in Parameter List............................................................................. 107
7.5.2 Group F1: Quick Start Parameter.................................................................................................... 108
7.5.3 Group F2: Input and Output Parameter........................................................................................... 108
7.5.4 Group F3: Controller Parameter...................................................................................................... 111
7.5.5 Group F4: Motor and Pump Settings............................................................................................... 112
7.5.6 Important EFC Parameters.............................................................................................................. 113
7.5.7 Auto-modified EFC Parameters in ASF Initialization....................................................................... 114
7.6 Fieldbus Communication.................................................................................................................... 115
DOK-SYTROX-DRN5020****-IT05-EN-P Bosch Rexroth AG III/143
Frequency-Controlled Pump Drive System Sytronix DRn 5020
Table of Contents

Page
7.6.1 Brief Introduction............................................................................................................................. 115
7.6.2 Frequency Converter Parameter Address....................................................................................... 116
8 Operation................................................................................................................... 117
8.1 General Information............................................................................................................................ 117
8.2 Modes................................................................................................................................................. 117
8.2.1 Standby Mode................................................................................................................................. 117
8.2.2 Parameter Mode.............................................................................................................................. 117
8.2.3 Operating Mode............................................................................................................................... 117
8.2.4 Error Mode....................................................................................................................................... 117
9 Maintenance.............................................................................................................. 118
9.1 System Overview................................................................................................................................ 118
9.2 Drive Controllers................................................................................................................................. 118
10 Decommissioning....................................................................................................... 119
11 Disassembly and Replacement................................................................................. 120
11.1 Disassembly....................................................................................................................................... 120
11.1.1 Preparing for Disassembly.............................................................................................................. 120
11.1.2 Disassembling the Hydraulic Product.............................................................................................. 120
11.2 Drive Controller................................................................................................................................... 120
12 Environmental protection and disposal ..................................................................... 121
12.1 Environmental protection.................................................................................................................... 121
12.2 Disposal.............................................................................................................................................. 121
13 Extension and Modification........................................................................................ 123
14 Troubleshooting......................................................................................................... 124
14.1 Display of LED Characters................................................................................................................. 124
14.2 Status Code........................................................................................................................................ 124
14.3 Warning Code..................................................................................................................................... 124
14.4 Error Code.......................................................................................................................................... 125
14.4.1 Error 1 (OC-1): Overcurrent at Constant Speed.............................................................................. 125
14.4.2 Error 2 (OC-2): Overcurrent during Acceleration............................................................................. 125
14.4.3 Error 3 (OC-3): Overcurrent during Deceleration............................................................................ 125
14.4.4 Error 4 (OE-1): Overvoltage at Constant Speed.............................................................................. 126
14.4.5 Error 5 (OE-2): Overvoltage during Acceleration............................................................................. 126
14.4.6 Error 6 (OE-3): Overvoltage during Deceleration............................................................................ 126
14.4.7 Error 7 (OE-4): Overvoltage during Stop......................................................................................... 126
14.4.8 Error 8 (UE-1): Undervoltage during Run........................................................................................ 127
14.4.9 Error 9 (SC): Surge Current or Short Circuit.................................................................................... 127
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Frequency-Controlled Pump Drive System Sytronix DRn 5020
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Page
14.4.10 Error 10 (IPH.L): Input Phase Loss................................................................................................. 127
14.4.11 Error 11 (OPH.L): Output Phase Loss............................................................................................. 127
14.4.12 Error 12 (ESS-): Soft Start Error...................................................................................................... 127
14.4.13 Error 20 (OL-1): Converter Overload............................................................................................... 128
14.4.14 Error 21 (OH): Converter over Temperature................................................................................... 128
14.4.15 Error 22 (UH): Converter under Temperature................................................................................. 128
14.4.16 Error 23 (FF): Fan Failure................................................................................................................ 128
14.4.17 Error 30 (OL-2): Motor Overload..................................................................................................... 129
14.4.18 Error 31 (Ot): Motor over Temperature............................................................................................ 129
14.4.19 Error 32 (t-Er): Motor Parameter Tuning Error................................................................................ 129
14.4.20 Error 33 (AdE-): Synchronous Motor Angle Detection Error............................................................ 129
14.4.21 Error 38 (AibE): Analog Input Broken Wire Detection..................................................................... 130
14.4.22 Error 39 (EPS-): DC_IN Power Supply Error................................................................................... 130
14.4.23 Error 40 (dir1): Forward Running Lock Error................................................................................... 130
14.4.24 Error 41 (dir2): Reverse Running Lock Error................................................................................... 130
14.4.25 Error 42 (E-St): Terminal Error Signal............................................................................................. 130
14.4.26 Error 43 (FFE-): Firmware Version Mismatch.................................................................................. 130
14.4.27 Error 44 (rS-): Modbus Communication Error.................................................................................. 131
14.4.28 Error 45 (E.Par): Parameter Settings Invalid................................................................................... 131
14.4.29 Error 46 (U.Par): Unknown Parameter Restore Error...................................................................... 131
14.4.30 Error 48 (idA-): Internal Communication Error................................................................................. 131
14.4.31 Error 49 (idP-): Internal Parameter Error......................................................................................... 131
14.4.32 Error 50 (idE-): Converter Internal Error.......................................................................................... 131
14.4.33 Error 51 (OCd-): Extension Card Internal Error............................................................................... 131
14.4.34 Error 52 (OCc): Extension Card PDOs Configuration Error............................................................ 131
14.4.35 Error 53 (Fdi-): No Valid Process Data............................................................................................ 132
14.4.36 Error 54 (PcE-): Remote Control Communication Error.................................................................. 132
14.4.37 Error 55 (PbrE): Parameter Backup / Restore Error........................................................................ 132
14.4.38 Error 56 (PrEF): Parameter Restore Error after Firmware Update.................................................. 132
14.4.39 Error 60 (ASF-): Application Firmware Error................................................................................... 132
14.4.40 Error 61 (APE1): Application Error.................................................................................................. 132
14.5 Diagnosis............................................................................................................................................ 133
14.5.1 Warnings......................................................................................................................................... 133
14.5.2 Error Code....................................................................................................................................... 136
14.5.3 Monitoring Parameter...................................................................................................................... 138
14.5.4 General DRn system troubleshooting.............................................................................................. 139
15 Service and support................................................................................................... 140
15.1 Sales and Service Network................................................................................................................. 140
15.2 Internet Contact.................................................................................................................................. 140
15.3 Preparation of Information.................................................................................................................. 140
Index.......................................................................................................................... 141
DOK-SYTROX-DRN5020****-IT05-EN-P Bosch Rexroth AG V/143
Frequency-Controlled Pump Drive System Sytronix DRn 5020
Table of Contents

Bosch Rexroth AG DOK-SYTROX-DRN5020****-IT05-EN-PVI/143
Frequency-Controlled Pump Drive System Sytronix DRn 5020

1 About this Documentation
1.1 Validity of the Documentation
This documentation applies to the variable speed pump drives, Sytronix DRn
5020 and with drive controllers Rexroth EFC5610.
The content of this documentation focuses on information on the electric
drive system. Motors and pumps are described in separate instruction man‐
uals. Where required, this documentation may refer to the amending docu‐
mentations.
This documentation contains important information on the safe and proper
transport, assembly, commissioning, maintenance, disassembly and simple
troubleshooting of the product.
● You should read this documentation completely and in particular chapter
2 "Safety Instructions" on page 11 before working with the product.
This documentation is valid for DRn 5020 systems with Rexroth
frequency converter EFC 5610 with firmware of version 03V08
and higher and with Sytronix ASF of version FWS-XFC01*-
C14-02VRS-NN and higher.
DOK-SYTROX-DRN5020****-IT05-EN-P Bosch Rexroth AG 7/143
Frequency-Controlled Pump Drive System Sytronix DRn 5020
About this Documentation

1.2 Required and Amending Documentation
The product must not be commissioned until you have been provided with the
following documentations and you have understood and observed them.
Title Document number Document type Catalog
Sytronix DRn 5020 Frequency-Controlled Pump
Drive System R912007127 Quick Start Guide
Controller / Converter
Rexroth Frequency Converter EFC 3610 / EFC
5610 Series R912005856 Quick Start Guide
Rexroth Frequency Converter EFC 3610 / EFC
5610 Series R912005854 Operating Instructions
Rexroth Frequency Converter Multi-Ethernet Card R912006860 Instruction Manual
Rexroth Frequency Converter EFC x610 Series
Brake Chopper R912007235 Operating Instructions
Sytronix-variable-speed pump drives R999000332 Data sheet System Catalog
Pressure transducer with integrated electronics-
type HM20 30272 Data sheet Presssure Sensor
Rexroth IndraDyn E Standard Motors MOT-FC for
Frequency Converter Operation R911343624 Project planning manual Motor
Variable-Speed Drive, Fixed Displacement, type
A10 91485 Data sheet
Pump
Axial Piston Variable Pumps A10VO, A10VSO,
A10VSNO 92714-01-B Instruction manual
Variable-Speed Drive, Fixed Displacement, type
A4 92050 Data sheet
Axial piston variable pump A4VSO 92050-01-B Operating instructions
Rexroth Sytronix Mounting and Commissioning
Axial Piston Variable Pump-A10VZO / A10VSO /
A4VSO
R911341629 Mounting instructions Pump Mounting
Control Cabinet: climate control, EMC, setup, de‐
gree of protection, electrics, IndraDrive, Rexroth
Fv, Sytronix
R911344988 Project planning manual Cabinet Planning
Tab. 1-1: Required and amending documentation
1. Only Quick Start Guide for DRn 5020 and EFC converter
(Row 1 and 2) will be printed and delivered with EFC con‐
verter for Sytronix, for more information about the controller /
converter please refer to the document of row 3 and this
document, which can be downloaded or purchased by
Bosch Rexroth.
2. Since the Sytronix controller have been embedded to EFC
converter, both documents (Sytronix DRn 5020 and EFC
5610) are needed for operating the controller / converter.
Bosch Rexroth AG DOK-SYTROX-DRN5020****-IT05-EN-P8/143
Frequency-Controlled Pump Drive System Sytronix DRn 5020
About this Documentation