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