REXROTH Sytronix FcP 5020 User manual

Frequency-controlled pump
drive system
Sytronix FcP 5020
Operating Instructions
R912008034
Edition 01

Frequency-controlled pump drive system
Sytronix FcP 5020
Operating Instructions
DOK-SYTROX-FCP5020****-IT01-EN-P
RS-d62fe0bdaeba91830a347ea500548643-1-en-US-10
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.
Title
Type of Documentation
Document Typecode
Internal File Reference
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P
Frequency-controlled pump drive system Sytronix FcP 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.............................................................................................................. 10
1.3.1 Consistency....................................................................................................................................... 10
1.3.2 Safety Instructions............................................................................................................................. 10
1.3.3 Symbols............................................................................................................................................. 11
1.3.4 Abbreviations..................................................................................................................................... 11
2 Safety Instructions....................................................................................................... 13
2.1 General Information on this Chapter..................................................................................................... 13
2.2 Intended Use........................................................................................................................................ 13
2.3 Improper Use........................................................................................................................................ 13
2.4 Qualification of Personnel..................................................................................................................... 14
2.5 General Safety Instructions.................................................................................................................. 14
2.6 Product- and Technology-dependent Safety Instructions..................................................................... 15
2.7 Obligations of the Machine End-user.................................................................................................... 17
3 Safety Instructions for Electric Drives and Controls..................................................... 19
3.1 Definitions of Terms.............................................................................................................................. 19
3.2 General Information.............................................................................................................................. 21
3.2.1 Using the Safety Instructions and Passing them on to Others.......................................................... 21
3.2.2 Requirements for Safe Use............................................................................................................... 21
3.2.3 Hazards by Improper Use.................................................................................................................. 22
3.3 Instructions with Regard to Specific Dangers....................................................................................... 23
3.3.1 Protection against Contact with Electrical Parts and Housings......................................................... 23
3.3.2 Protective Extra-low Voltage as Protection against Electric Shock .................................................. 24
3.3.3 Protection against Dangerous Movements........................................................................................ 25
3.3.4 Protection against Electromagnetic and Magnetic Fields during Operation and Mounting............... 26
3.3.5 Protection against Contact with Hot Parts......................................................................................... 27
3.3.6 Protection during Handling and Mounting......................................................................................... 27
3.3.7 Battery Safety.................................................................................................................................... 28
3.3.8 Protection against Pressurized Systems........................................................................................... 28
3.3.9 General Warnings of Damage to Property and Damage to the Product........................................... 29
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 31
4 About this Product........................................................................................................ 33
4.1 Product Description.............................................................................................................................. 33
4.2 Component Overview........................................................................................................................... 34
4.2.1 System Components Example.......................................................................................................... 34
4.2.2 Installation of EFC for FcP in a Cabinet............................................................................................ 35
4.3 Type Code and Label of EFC 5610 for FcP 5020................................................................................. 36
4.3.1 Frequency Converter Type Code Description................................................................................... 36
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG I/201
Frequency-controlled pump drive system Sytronix FcP 5020
Table of Contents

Page
4.3.2 FcP 5020 ASF Type Code Description.............................................................................................. 38
4.3.3 Version Matching Table..................................................................................................................... 39
4.4 Input and Output Allocation at the Frequency Converter...................................................................... 40
4.4.1 Standard Wiring Diagram.................................................................................................................. 40
4.4.2 Control Terminals Description........................................................................................................... 41
Digital inputs................................................................................................................................... 41
Analog inputs.................................................................................................................................. 41
Digital outputs................................................................................................................................. 42
Analog outputs................................................................................................................................ 42
4.4.3 Power Terminal................................................................................................................................. 42
4.4.4 Control Terminals.............................................................................................................................. 44
Control terminals figure.................................................................................................................. 44
5 Transport and Storage................................................................................................. 45
6 Assembly and Installation............................................................................................ 47
6.1 General Information.............................................................................................................................. 47
6.2 Unpacking............................................................................................................................................. 47
6.3 Installation Conditions........................................................................................................................... 47
6.3.1 Installation Conditions for Motor Pump Unit...................................................................................... 47
6.3.2 Installation Conditions for Frequency Converter and Additional Components.................................. 48
6.4 Assembling the FcP System................................................................................................................. 49
6.4.1 Mechanically Connecting the Motor Pump Unit................................................................................. 49
6.4.2 Hydraulically Connecting the Motor Pump Unit................................................................................. 49
6.4.3 Connection Technique....................................................................................................................... 50
General Notes................................................................................................................................ 50
Power Connection.......................................................................................................................... 52
Connect the Motor Fan................................................................................................................... 56
6.4.4 Connection EFC 5610 for FcP 5020.................................................................................................. 57
Digital input NPN / PNP wiring....................................................................................................... 57
Digital output DO1a, DO1b load pull-up / pull-down wiring............................................................ 58
Relay output terminals.................................................................................................................... 58
6.4.5 Connection of the Pressure Transducer............................................................................................ 60
6.4.6 Electronic Component Assembly and Installation in Control Cabinet................................................ 61
7 Commissioning of Sytronix FcP 5020 System............................................................. 63
7.1 Introduction and Basics........................................................................................................................ 63
7.1.1 Application type................................................................................................................................. 63
7.1.2 Functional characteristics.................................................................................................................. 64
7.2 Getting started with FcP 5020.............................................................................................................. 65
7.2.1 Notes on Commissioning................................................................................................................... 65
7.2.2 Hydraulic System Preparation........................................................................................................... 65
7.2.3 Electric Hardware Connection Preparation....................................................................................... 66
7.2.4 Operating Preparation....................................................................................................................... 66
7.2.5 Relevant Parameters......................................................................................................................... 67
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-PII/201
Frequency-controlled pump drive system Sytronix FcP 5020
Table of Contents

Page
7.2.6 Starting with FcP 5020 dialog............................................................................................................ 68
7.2.7 Converter I/O Configuration............................................................................................................... 71
Analog Input AI1............................................................................................................................. 71
Quick Configuration For Rexroth HM20 Pressure Sensor.............................................................. 74
Analog Input AI2............................................................................................................................. 76
Analog Output AO1........................................................................................................................ 77
Digital Input..................................................................................................................................... 78
Digital and Relay Output................................................................................................................. 79
7.2.8 Quick Configuration For Rexroth MOT-FC_HOY Motor ................................................................... 80
7.2.9 First Commissioning.......................................................................................................................... 83
7.3 Commissioning (advanced).................................................................................................................. 85
7.3.1 Overview of Main Functions.............................................................................................................. 85
7.3.2 pQ Controller Parameter Setting....................................................................................................... 87
Overview and introduction.............................................................................................................. 87
7.3.3 Enhanced Parameter Setting............................................................................................................ 94
Overview and introduction.............................................................................................................. 94
Easy command setting: internal parameter, selectable pressure command.................................. 94
Control parameter selection: free selectable parameter sets (2 sets)............................................ 95
Switching integral time Ti................................................................................................................ 96
Minimum flow and minimum pressure............................................................................................ 97
7.4 Extension Functions............................................................................................................................. 98
7.4.1 Pump Extended Function.................................................................................................................. 98
7.4.2 Master / Slave Function..................................................................................................................... 99
7.4.3 Sleep / Wake Function.................................................................................................................... 101
7.4.4 Two Points / Double Pump Control................................................................................................. 103
7.4.5 Pressure Drop / Overshoot Compensation...................................................................................... 105
7.4.6 Pump Power Limitation.................................................................................................................... 106
7.4.7 Hydraulic Soft Start and Separate Acceleration Ramp.................................................................... 107
7.5 Protection Function............................................................................................................................. 108
7.5.1 Condition Monitoring and Protection............................................................................................... 108
7.5.2 Overview.......................................................................................................................................... 109
7.5.3 Pressure Sensor Failure Detection.................................................................................................. 109
7.5.4 Actual Pressure Monitoring............................................................................................................. 112
7.5.5 Oil Change Warning / Error Function.............................................................................................. 113
7.5.6 Pressure and Flow Command Limit................................................................................................ 114
7.5.7 Pump Thermal Protection................................................................................................................ 115
7.5.8 Sensor Monitoring........................................................................................................................... 116
7.6 CytroPac Configuration....................................................................................................................... 117
7.6.1 Overview.......................................................................................................................................... 117
7.6.2 Load CytroPac Configuration.......................................................................................................... 117
7.6.3 CytroPac Sensor Monitoring ........................................................................................................... 117
7.6.4 LED Flash Showing Converter Status............................................................................................. 118
7.7 myCro Configuration........................................................................................................................... 119
7.7.1 Overview.......................................................................................................................................... 119
7.7.2 Load myCro Configuration............................................................................................................... 119
7.7.3 myCro Function Description............................................................................................................ 123
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG III/201
Frequency-controlled pump drive system Sytronix FcP 5020
Table of Contents

Page
7.8 Fieldbus Communication.................................................................................................................... 124
7.8.1 Brief Introduction............................................................................................................................. 124
7.8.2 Frequency Converter Parameter Address....................................................................................... 124
7.8.3 Loading Process Data via Dialog.................................................................................................... 126
7.9 Additional Notes.................................................................................................................................. 128
7.9.1 Motor Thermal Model Protection..................................................................................................... 128
7.9.2 Motor Thermal Protection with Temperature Sensor....................................................................... 129
7.9.3 Commissioning Tool........................................................................................................................ 130
7.10 FcP 5020 Parameter List.................................................................................................................... 131
7.10.1 Terminology and Abbreviation in Parameter List............................................................................. 131
7.10.2 Group F1: Quick Start Parameter.................................................................................................... 132
7.10.3 Group F2: Input and Output Parameter........................................................................................... 134
7.10.4 Group F3: p/Q PID Parameter......................................................................................................... 137
7.10.5 Group F4: System Protection and Pump Function Parameter........................................................ 138
7.10.6 Auto-modified EFC Parameters in FcP Initialization........................................................................ 140
7.10.7 Changed Setting Parameter by Load CytroPac Configuration........................................................ 141
7.10.8 Monitoring Parameter...................................................................................................................... 143
7.11 EFC Parameter List............................................................................................................................ 144
7.11.1 Terminology and Abbreviation in Parameter List............................................................................. 144
7.11.2 Group b: System Parameters.......................................................................................................... 144
b0: Basic system parameters....................................................................................................... 144
7.11.3 Group C: Power Parameters........................................................................................................... 145
C0: Power control parameters...................................................................................................... 145
C1: Motor and system parameters............................................................................................... 147
C2: V/f control parameters............................................................................................................ 148
C3*: Vector control parameters.................................................................................................... 149
7.11.4 Group E: Function Control Parameters........................................................................................... 150
E0: Set point and control parameters........................................................................................... 150
E1: Input terminal parameters...................................................................................................... 153
E2: Output terminal parameters................................................................................................... 156
E5: Extended function parameters............................................................................................... 158
E8: Standard communication parameters.................................................................................... 159
E9: Protection and error parameters............................................................................................ 160
7.11.5 Group F0: ASF Parameters............................................................................................................. 162
7.11.6 Group H: Extension Card Parameters............................................................................................. 163
H0: Extension card general parameters....................................................................................... 163
H1: Communication card parameters........................................................................................... 164
H8: I/O card parameters............................................................................................................... 166
H9: Relay card parameters........................................................................................................... 169
7.11.7 Group U: Panel Parameters............................................................................................................ 170
U0: General panel parameters..................................................................................................... 170
U1: LED panel parameters........................................................................................................... 170
U2: LCD panel parameters........................................................................................................... 171
7.11.8 Group d0: Monitoring Parameters................................................................................................... 174
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-PIV/201
Frequency-controlled pump drive system Sytronix FcP 5020
Table of Contents

Page
8 Operation................................................................................................................... 177
8.1 General Information............................................................................................................................ 177
8.2 Modes................................................................................................................................................. 177
8.2.1 Standby / Parameter Mode.............................................................................................................. 177
8.2.2 Operating Mode............................................................................................................................... 177
8.2.3 Error Mode....................................................................................................................................... 177
9 Maintenance.............................................................................................................. 179
9.1 System Overview................................................................................................................................ 179
9.2 Drive Controllers................................................................................................................................. 179
9.3 Motor-pump Unit................................................................................................................................. 179
10 Decommissioning....................................................................................................... 180
11 Disassembly and Replacement................................................................................. 181
11.1 Disassembly....................................................................................................................................... 181
11.1.1 Preparing for Disassembly.............................................................................................................. 181
11.1.2 Disassembling the Hydraulic Product.............................................................................................. 181
11.2 Motor-pump Unit................................................................................................................................. 182
11.3 Drive Controller................................................................................................................................... 182
12 Environmental protection and disposal ..................................................................... 183
12.1 Environmental protection.................................................................................................................... 183
12.2 Disposal.............................................................................................................................................. 183
13 Extension and Modification........................................................................................ 185
14 Troubleshooting......................................................................................................... 187
14.1 Display of LED Characters................................................................................................................. 187
14.2 Status Code........................................................................................................................................ 187
14.3 EFC Warning Code............................................................................................................................. 187
14.4 EFC Error Code.................................................................................................................................. 188
14.4.1 Error 1 (OC-1): Overcurrent at Constant Speed.............................................................................. 188
14.4.2 Error 2 (OC-2): Overcurrent during Acceleration............................................................................. 188
14.4.3 Error 3 (OC-3): Overcurrent during Deceleration............................................................................ 188
14.4.4 Error 4 (OE-1): Overvoltage at Constant Speed.............................................................................. 189
14.4.5 Error 5 (OE-2): Overvoltage during Acceleration............................................................................. 189
14.4.6 Error 6 (OE-3): Overvoltage during Deceleration............................................................................ 189
14.4.7 Error 7 (OE-4): Overvoltage during Stop......................................................................................... 189
14.4.8 Error 8 (UE-1): Undervoltage during Run........................................................................................ 189
14.4.9 Error 9 (SC): Surge Current or Short Circuit.................................................................................... 190
14.4.10 Error 10 (IPH.L): Input Phase Loss................................................................................................. 190
14.4.11 Error 11 (OPH.L): Output Phase Loss............................................................................................. 190
14.4.12 Error 12 (ESS-): Soft Start Error...................................................................................................... 190
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG V/201
Frequency-controlled pump drive system Sytronix FcP 5020
Table of Contents

Page
14.4.13 Error 20 (OL-1): Converter Overload............................................................................................... 190
14.4.14 Error 21 (OH): Converter over Temperature................................................................................... 191
14.4.15 Error 22 (UH): Converter under Temperature................................................................................. 191
14.4.16 Error 23 (FF): Fan Failure................................................................................................................ 191
14.4.17 Error 24 (Pdr): Pump Dry................................................................................................................. 191
14.4.18 Error 25 (CoL-): Command Value Lost ........................................................................................... 191
14.4.19 Error 30 (OL-2): Motor Overload..................................................................................................... 192
14.4.20 Error 31 (Ot): Motor over Temperature............................................................................................ 192
14.4.21 Error 32 (t-Er): Motor Parameter Tuning Error................................................................................ 192
14.4.22 Error 33 (AdE-): Synchronous Motor Angle Detection Error............................................................ 192
14.4.23 Error 38 (AibE): Analog Input Broken Wire Detection..................................................................... 193
14.4.24 Error 39 (EPS-): DC_IN Power Supply Error................................................................................... 193
14.4.25 Error 40 (dir1): Forward Running Lock Error................................................................................... 193
14.4.26 Error 41 (dir2): Reverse Running Lock Error................................................................................... 193
14.4.27 Error 42 (E-St): Terminal Error Signal............................................................................................. 193
14.4.28 Error 43 (FFE-): Firmware Version Mismatch.................................................................................. 193
14.4.29 Error 44 (rS-): Modbus Communication Error.................................................................................. 194
14.4.30 Error 45 (E.Par): Parameter Settings Invalid................................................................................... 194
14.4.31 Error 46 (U.Par): Unknown Parameter Restore Error...................................................................... 194
14.4.32 Error 48 (idA-): Internal Communication Error................................................................................. 194
14.4.33 Error 49 (idP-): Internal Parameter Error......................................................................................... 194
14.4.34 Error 50 (idE-): Converter Internal Error.......................................................................................... 194
14.4.35 Error 51 (OCd-): Extension Card Internal Error............................................................................... 194
14.4.36 Error 52 (OCc): Extension Card PDOs Configuration Error............................................................ 194
14.4.37 Error 53 (Fdi-): No Valid Process Data............................................................................................ 195
14.4.38 Error 54 (PcE-): Remote Control Communication Error.................................................................. 195
14.4.39 Error 55 (PbrE): Parameter Backup / Restore Error........................................................................ 195
14.4.40 Error 56 (PrEF): Parameter Restore Error after Firmware Update.................................................. 195
14.4.41 Error 60 (ASF-): Application Firmware Error................................................................................... 195
14.4.42 Error 61...65 (APE1...APE5): Application Error............................................................................... 195
14.5 Sytronix Warning Code....................................................................................................................... 196
14.6 Sytronix Error Code............................................................................................................................ 197
15 Service and support................................................................................................... 198
15.1 Sales and Service Network................................................................................................................. 198
15.2 Internet Contact.................................................................................................................................. 198
15.3 Preparation of Information.................................................................................................................. 198
Index.......................................................................................................................... 199
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-PVI/201
Frequency-controlled pump drive system Sytronix FcP 5020
Table of Contents

1 About this Documentation
1.1 Validity of the Documentation
This documentation applies to the following products:
SYT-FCP5020-XXXXXX-X-FC2XXXXX-EFXXX-XXXX
This documentation is intended for assemblers, operators, service engineers
and system end-users.
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 13 before working with the product.
This documentation is valid for FcP 5020 systems with Rexroth
frequency converter EFC 5610 with firmware of version 03V24
and higher and with Sytronix ASF of version 01V12 or higher.
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG 7/201
Frequency-controlled pump drive system Sytronix FcP 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 FcP 5020 Frequency-Controlled Pump
Drive System R912006684 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 CANopen Card R912006713 Instruction Manual
Rexroth Frequency Converter Multi-Ethernet Card R912006860 Instruction Manual
I/O & Relay Card R912006326 Product Insert
Brake Chopper R912007235 Operating Instructions
Sytronix-variable-speed pump drives R999000331 Data sheet System Catalog
Pressure transducer with integrated electronics-
type HM20 30272 Data sheet Pressure Sensor
Rexroth IndraDyn E Standard Motors MOT-FC for
Frequency Converter Operation R911343624 Project planning manual Motor
Rexroth Sytronix Safety Notes and Instructions on
Use Motor-Pump Unit R911343643 Safety notes Motor-Pump Unit
Internal gear pump PGF Series 2X and 3X 10213 Data sheet
Pump
Rexroth Sytronix, mounting and commissioning,
Internal gear pump PGH / PGM / PGF R911340908 Mounting instructions
Internal gear pump, fixed displacement, type PGH 10227 Data sheet
Internal gear pump, type PGH.-3X 10227-B Operating instructions
Variable-Speed Drive, Fixed Displacement, type
A10 91485 Data sheet
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
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
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P8/201
Frequency-controlled pump drive system Sytronix FcP 5020
About this Documentation

1. Only Quick Start Guide for FcP 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 R912005854, this document can be
downloaded or purchased from Bosch Rexroth.
2. Since the sytronix controller have been embedded to EFC
converter, both documents (Sytronix FcP 5020 and EFC
5610) are needed for operating the controller / converter.
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG 9/201
Frequency-controlled pump drive system Sytronix FcP 5020
About this Documentation

1.3 Representation of Information
1.3.1 Consistency
Consistent safety instructions, symbols, terms and abbreviations are used so
that you can quickly and safely work with your product using this documenta‐
tion. For a better understanding, they are explained in the following sections.
1.3.2 Safety Instructions
In this documentation, safety instructions are included whenever sequences
of actions are explained which bear the danger of personal injury or damage
to property. The hazard avoidance measures described must be observed.
Safety instructions are structured as follows:
SIGNAL WORD
Type and source of danger
Consequences in case of non-compliance
● Hazard avoidance measures
● <Enumeration>
●Warning sign: Draws attention to the danger
●Signal word: Identifies the degree of danger
●Type and source of danger: Identifies the type and source of danger
●Consequences: Describes the consequences of non-compliance
●Precaution: Specifies how the hazard can be prevented
Risk classes according to ANSI Z535.6-2006
DANGER
Indicates a dangerous situation which will cause death or severe injuries if
not prevented.
WARNING
Indicates a dangerous situation which may cause death or severe injuries if
not prevented.
CAUTION
Indicates a dangerous situation which may cause minor to medium injuries if
not prevented.
NOTICE
Indicates damage to property: The product or the environment could be dam‐
aged.
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P10/201
Frequency-controlled pump drive system Sytronix FcP 5020
About this Documentation

1.3.3 Symbols
The following symbols indicate notices which are not safety-relevant but in‐
crease the comprehensibility of the documentation.
Symbol Meaning
If this information is not observed, the product cannot be used
and/or operated optimally.
• Single, independent action.
1.
2.
3.
Numbered instruction: The numbers indicate that the actions
must be carried out one after the other.
Tab. 1-2: Meaning of the symbols
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Abbreviation Meaning
FcP system Frequency controlled pump system
p Pressure
Q Flow rate
n Speed
PGF/PGH/PGM Internal gear pump, constant displacement volume
RE Rexroth document in English language
RX Rexroth document in another language
ESD/EMC Electrostatic discharge/electro-magnetic compatibility
CPU Central processing unit, processor
EFC Frequency converter
Vg Displacement of the pump
ASF Application Specific Firmware, application control software for
EFC frequency converter
Tab. 1-3: Abbreviations
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG 11/201
Frequency-controlled pump drive system Sytronix FcP 5020
About this Documentation

Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P12/201
Frequency-controlled pump drive system Sytronix FcP 5020

2 Safety Instructions
2.1 General Information on this Chapter
The product has been manufactured according to the generally accepted co‐
des of practice. However, there is still the risk of personal injury and 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 product
on to third parties.
2.2 Intended Use
This product is an electrohydrostatic drive system.
The FcP system is exclusively intended to be installed in a machine or to be
assembled together with other components to form a machine and/or a pow‐
er unit. The FcP system may only be commissioned after it has been integra‐
ted into the machine for which it is designed.
The FcP system may be used as follows:
● For pressure-controlled hydraulic supply with override flow control
The FcP system is not suitable for performing safety-relevant functions.
A plausibility check of the command and actual values (pressure
and speed) is not provided for in the FcP system.
● Make sure that the plausibility check is carried out in the ma‐
chine control.
In order to carry out an application-specific adjustment of the parameters
within the scope of the initial commissioning, please contact your Bosch
Rexroth application engineer.
The product is only intended for professional use and not for private use. In‐
tended use includes having read and understood this documentation com‐
pletely, especially this chapter.
2.3 Improper Use
Any use deviating from the intended use is improper and thus not admissible.
Bosch Rexroth AG does not assume any liability for damage caused by im‐
proper use. The user assumes all risks involved with improper use.
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG 13/201
Frequency-controlled pump drive system Sytronix FcP 5020
Safety Instructions

2.4 Qualification of Personnel
The activities described in this documentation require basic knowledge of
mechanics, hydraulics and electrics as well as knowledge of the appropriate
technical terms. For transporting and handling the product, additional knowl‐
edge of how to handle lifting tools and the necessary attachment devices is
required. In order to ensure safe use, these activities may only be carried out
by an expert in the field or an instructed person under the direction and su‐
pervision of an expert.
Experts are persons who are able to recognize potential dangers and take
appropriate safety measures due to their technical training, knowledge and
experience, as well as their knowledge of the relevant regulations pertaining
to the work to be undertaken. An expert must observe the relevant specific
professional rules.
The following is required as additional qualification:
● Knowledge of the wiring of the electric components
● Knowledge of the application software parameterization
● Basic control technology knowledge
2.5 General Safety Instructions
● Observe the valid regulations on accident prevention and for environ‐
mental protection.
● Observe the safety regulations and provisions of the country where the
product is implemented/used.
● Exclusively use Rexroth products in technically perfect condition.
● Observe all notices on the product.
● Persons who assemble, operate, disassemble or maintain Rexroth prod‐
ucts must not be under the influence of alcohol, other drugs or pharma‐
ceuticals that may affect their ability to react.
● Only use accessories and spare parts authorized by the manufacturer in
order to exclude hazards to persons due to inappropriate spare parts.
● Comply with the technical data and environmental conditions indicated
in the product documentation.
● The installation or use of inappropriate products in safety-relevant appli‐
cations could result in unintended operating states when being used
which in turn could cause personal injuries and/or damage to property.
Therefore, only use a product for safety-relevant applications if this use
is expressly specified and permitted in the documentation of the prod‐
uct.
● Do not commission the product until you can be sure that the end prod‐
uct (for example a machine or system) where the Rexroth product is in‐
stalled complies with the country-specific provisions, safety regulations
and standards of application.
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P14/201
Frequency-controlled pump drive system Sytronix FcP 5020
Safety Instructions

2.6 Product- and Technology-dependent Safety Instructions
WARNING
Pressurized system!
Danger to life, risk of injury, severe injury when working on systems that have
not been stopped! Damage to property!
● Ensure that the FcP system and/or the machine is completely depres‐
surized.
● Do not disconnect line connections, connections or components as long
as the FcP system is pressurized.
● Switch off all force-transmitting components and ports (electric, pneu‐
matic, hydraulic) according to the manufacturer's specifications and se‐
cure them against restarting. If possible, remove the mains fuse of the
system.
WARNING
Leaking oil mist due to defective or improperly assembled seals!
Risk of fire, risk of explosion, danger due to allergic reactions, environmental
pollution!
● Welding work may only be carried out when the FcP system is depres‐
surized.
● Keep open fire and ignition sources away from the FcP system.
WARNING
High electrical voltage (above 50 V)!
Danger to life, risk of injury caused by electric shock or severe injury!
● Make sure the relevant system part is de-energized before assembling
the FcP system or connecting and disconnecting connectors.
● Protect the system against restarting.
● Only carry out short-time measurements and tests with permanently
connected protective grounding conductor at those points of the compo‐
nents intended for this purpose.
● After switch-off, you should generally wait for 30 minutes before you
touch an electric component in order to allow the live capacitors to dis‐
charge. Measure the electrical voltage of live parts before beginning the
work in order to avoid hazards caused by contact.
● Do not touch the electrical connection points of the components if the
system is activated.
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG 15/201
Frequency-controlled pump drive system Sytronix FcP 5020
Safety Instructions

WARNING
High housing voltage and high leakage current!
Danger to life, risk of injury caused by electric shock or severe injury!
● Before switch-on and commissioning, ground the components of the
FcP system or connect them to the protective grounding conductors at
the grounding points.
● Always connect the protective grounding conductors of the FcP system
components permanently to the supply network. The leakage current is
greater than 3.5 mA.
● Use at least a 10 mm² copper cross-section for the entire route of the
protective grounding conductor.
WARNING
Exposure to magnetic and electro-magnetic fields!
Health hazard for persons with cardiac pacemakers, metal implants and
hearing aids in the immediate vicinity of electric components!
● Ban the group of persons specified above from entering the following
areas:
– Areas in which components of the FcP system are mounted, com‐
missioned and operated
– Areas in which motor parts with permanent solenoids are stored,
repaired or mounted
● Consult a doctor if the persons specified above have to work in these
areas.
CAUTION
Hot FcP system surfaces!
Risk of burning! Risk of injury!
● Only touch the surfaces of the FcP system with protective gloves or do
not work on hot surfaces.
During or after the operation, temperatures may rise to values higher
than 60 °C (140 °F), depending on the operating conditions.
● Allow the FcP system to cool down sufficiently before touching it.
● Observe the protective measures of the end machine manufacturer.
CAUTION
Slip hazard due to oily surfaces!
Risk of injury!
● Protect and mark the danger zone.
● Use an oil binding agent in order to bind the leaked hydraulic fluid.
● Remove and dispose of the contaminated oil binding agent (see chapter
12 "Environmental protection and disposal " on page 183).
● Wear your protective equipment, such as safety shoes.
Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P16/201
Frequency-controlled pump drive system Sytronix FcP 5020
Safety Instructions

CAUTION
Hydraulic fluid leaking from the FcP system in an uncontrolled form (due to
leakage)!
Risk of injury!
● Switch the machine off immediately (emergency stop switch).
● Identify and remedy the cause of the leakage.
● Never try to stop or seal the leak or the oil jet using a cloth.
● Never come into contact with a splashing high-pressure oil jet under any
circumstances.
● Carry out visual inspections for leak-tightness of the FcP system and the
oil containing components on a regular basis.
CAUTION
Contact with hydraulic fluid!
Health hazard / impairment of health, e.g. eye injuries, skin lesions, poisoning
when inhaled!
● Avoid contact with hydraulic fluids.
● When dealing with hydraulic fluids, you must observe the safety instruc‐
tions of the manufacturer.
● Use your personal protective equipment (e. g. safety goggles, protective
gloves, suitable working clothes, safety shoes).
● If, nevertheless, hydraulic fluid comes into contact with the eyes or gets
into the bloodstream or is swallowed, please consult a doctor immedi‐
ately.
2.7 Obligations of the Machine End-user
The machine end-user of the products by Bosch Rexroth AG is obliged to
provide for personnel training on a regular basis regarding the following sub‐
jects:
● Observation and use of the operating instructions as well as the legal
regulations.
● Intended operation of the product.
● Observation of the instructions of factory security officers and of the
operating instructions of the machine end-user.
● Behavior in case of emergency.
Bosch Rexroth AG offers training support measures in specific
fields. You can find an overview of the training contents on the In‐
ternet at http://www.boschrexroth.com/didactic.
DOK-SYTROX-FCP5020****-IT01-EN-P Bosch Rexroth AG 17/201
Frequency-controlled pump drive system Sytronix FcP 5020
Safety Instructions

Bosch Rexroth AG DOK-SYTROX-FCP5020****-IT01-EN-P18/201
Frequency-controlled pump drive system Sytronix FcP 5020