REXROTH CytroPac User manual
Operating instructions
RE 51055-B/02.2021
Replaces: 06.17
English
Small power unit
CytroPac
The data specified only serve to describe
the product. If information on the use of the
product is given, it is only to be regarded as
application examples and recommendations.
Catalog specifications do not constitute
assured characteristics. The information given
does not release the user from the obligation
of own judgment and verification. It must be
remembered that our products are subject to a
natural process of wear and aging.
© This document, as well as the data,
specifications and other information set forth in
it, are the exclusive property of Bosch Rexroth
AG. It may not be reproduced or given to third
parties without its consent.
The cover shows an example configuration. The
product supplied may differ from the solution
shown here.
The original operating instructions were
prepared in German.
CytroPac, RE 51055-B/02.2021, Bosch Rexroth AG
3/76Content
Content
1 About this documentation 6
1.1 Validity of the documentation 6
1.2 Required and supplementary documentation 6
1.3 Representation of information 7
1.3.1 Safety instructions 7
1.3.2 Symbols 7
1.3.3 Abbreviations used 8
2 Safety instructions 9
2.1 About this chapter 9
2.2 Intended use 9
2.3 Improper use 10
2.4 Qualification of personnel 10
2.5 General safety instructions 10
2.6 Product-specific safety instructions 11
2.7 Personal protective equipment 14
2.8 Obligations of the machine end-user 14
3 General notes on damage to property and damage to the product 16
4 Scope of delivery 18
5 About this product 19
5.1 Performance description 19
5.2 Product description 20
5.3 Components overview 21
5.4 Circuit diagram, hydraulic 22
5.5 Identification of the product 23
6 Transport and storage 24
6.1 Transporting the hydraulic power unit 24
6.1.1 Preparing for transport 25
6.1.2 Transport using forklifts and similar industrial trucks 25
6.1.3 Transport using lifting gear 26
6.2 Storing the hydraulic power unit 27
7 Mounting 28
7.1 Unpacking the hydraulic power unit 28
7.2 Erecting the hydraulic power unit 28
7.2.1 Dimensions of the hydraulic power unit 29
7.2.2 Fixation of the hydraulic power unit 30
7.3 Connecting the hydraulic supply 34
7.4 Connecting the water supply 35
7.5 Electrical interface assignment 36
7.5.1 Pinout of the mating connector to connection 12X1:
Feed-in/voltage supply 37
7.5.2 Mating connector pinout to port 15X1:
Enable signal 24VDC (M12 x 1, customer side) 38
7.5.3 Mating connector pinout: Fill level/temperature sensor, filter clogging
sensors ("Basic" configuration) 39
7.5.4 Mating connector pinout to port 15X1:
Enable signal 24VDC (M12 x 1, customer side) 40
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7.5.5 Mini USB service interface 14X1 to frequency converter
("Advanced" and "Premium" configuration) 41
7.5.6 Multi-Ethernet interfaces 41
7.5.7 Additional port Safe Torque Off (STO) 22X1 (optional) 42
7.6 Connecting electrical interfaces 43
7.6.1 "Basic" configuration 44
7.6.2 "Advanced" configuration 45
7.6.3 "Premium" configuration 45
7.6.4 All configurations 46
8 Commissioning 47
8.1 Initial commissioning 47
8.1.1 Before commissioning 47
8.1.2 Filling the hydraulic system 48
8.1.3 Bleeding the entire hydraulic system of the machine 49
8.1.4 Flushing the hydraulic system 49
8.2 Re-commissioning after longer standstill 50
9 Operation 50
10 Maintenance and repair 51
10.1 Cleaning and care 51
10.2 Inspection 51
10.3 Warning devices 52
10.4 Maintenance schedule 52
10.5 Maintenance 53
10.5.1 Checking the electrical components/installation 53
10.5.2 Fill level monitoring 53
10.5.3 Monitoring of the oil temperature 54
10.5.4 Filter element clogging monitoring (return flow filter) 54
10.5.5 Visual inspection of the filler breather filter (see Fig. 31, item 6) 55
10.5.6 Pressure value check 55
10.5.7 Hydraulic fluid care 55
10.5.8 Visual inspection for leakage, cracking, force effects and corrosion 56
10.5.9 Checking the heat exchanger 56
10.6 Spare and wear parts 57
11 Decommissioning 58
11.1 Preparing for decommissioning 58
11.2 Decommissioning process 58
12 Demounting and replacement 59
12.1 Preparing demounting 59
12.2 Demounting 59
13 Disposal 60
13.1 Environmental protection 60
14 Extension and modification 60
15 Troubleshooting 61
15.1 How to proceed for troubleshooting 61
15.1.1 Overview of the impact of defects 62
16 Technical data 64
17 Annex 64
17.1 List of addresses 64
17.2 Declaration of incorporation 65
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1 About this documentation
1.1 Validity of the documentation
This documentation is valid for the following product:
• Small power unit type CytroPac, for material numbers, refer to data sheet 51055.
This documentation is intended for fitters, operators, service technicians, system
operators and machine/plant manufacturers.
This documentation contains important information on the safe and proper
transport, mounting, commissioning, operation, use, maintenance, demounting and
simple troubleshooting of the product.
▶ Read this documentation thoroughly, especially Chapter 2 “Safety instructions“
and Chapter 3 “General notes on damage to property and damage to the
product“, before working with the hydraulic power unit.
1.2 Required and supplementary documentation
▶ Also observe the operating instructions and documentation of the overall
machine/system.
▶ The product must not be commissioned until you have been provided with the
documentation marked with the book symbol and you have understood and
observed it.
Table 1: Required and supplementary documentation
Title Document number Document type
Small power unit CytroPac
Contains technical data, operating conditions, performance limits and notes on
project planning
51055 Data sheet
CytroPac hydraulic power unit
Basic, Advanced, Premium, Commissioning instructions
51055-IB Commissioning
instructions
Hydraulic fluids based on mineral oils and related hydrocarbons
Describes the requirements for hydraulic fluids on mineral oil basis and related
hydrocarbons for operation with Rexroth hydraulic components and helps you to
select a hydraulic fluid for your hydraulic system
90220 Data sheet
Environmentally Acceptable Hydraulic Fluids
Application notes and requirements for Rexroth hydraulic components
90221 Data sheet
General product information on hydraulic products
Contains general information on hydraulic products
07008 Operating
instructions
Installation, commissioning and maintenance of hydraulic systems
Contains general information on the installation, commissioning and maintenance
of hydraulic systems
07900 Data sheet
External gear pumps AZPS-... 10095 Data sheet
Sytronix FcP 5020, Frequency-controlled pump drive system R912006684 Quick start guide
Frequency converter EFC 3610 / EFC 5610 R912005854 Operating
instructions
Frequency converter
Multi-Ethernet card
R912006860 Operating
instructions
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1.3 Representation of information
Consistent safety instructions, symbols, terms and abbreviations are used in this
documentation so that you can quickly and safely work with your hydraulic power
unit. For a better understanding, they are explained in the following sections.
1.3.1 Safety instructions
This documentation contains safety notes in chapter 2.6 “Product-specific safety
instructions“ and chapter 3 “General notes on damage to property and damage to
the product“ as well as before a sequence of activities or instructions for action,
which involve the risk of personal injury or damage to equipment. The 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 symbol: draws attention to a hazard
• Signal word: identifies the degree of hazard
• Type and source of danger: Specifies the type and source of danger
• Consequences: describes the consequences in case of non-compliance
• Precaution: Specifies how the danger can be prevented
Table 2: Hazard classifications according to ANSI Z535.6-2011
Warning sign, signal word Meaning
DANGER Indicates a hazardous situation which, if not avoided, will
certainly result in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE Damage to property: The product or the environment could
be damaged.
1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase the
comprehensibility of the documentation.
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Table 3: Meaning of the symbols
Symbol Meaning
If this information is disregarded, the product cannot be used or operated
in an optimum manner.
▶ Individual, independent action
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be carried out one after the
other.
1.3.3 Abbreviations used
The following abbreviations are used in this documentation:
Table 4: Abbreviations
Abbreviation Meaning
AB Aggregatebau (power unit construction)
BR Bosch Rexroth
DBV Druckbegrenzungsventil (pressure relief valve)
NG Size
PE Protective Earth
RE Rexroth document in English language
REXXXXXX-B Rexroth operating instructions in English language
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2 Safety instructions
2.1 About this chapter
The hydraulic power unit was designed and manufactured according to the generally
accepted code of practice. However, there is still a 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
hydraulic power unit.
▶ 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 hydraulic power
unit on to third parties.
Due to the interaction between the hydraulic power unit and the overall machinery/
system, the installation of the hydraulic power unit into the machine will result in
additional potential hazards.
This applies in particular to the influence of hydraulic and electrical controls on
hydraulic drives generating mechanical movements. It is therefore essential for the
manufacturer of the overall machinery/system to have conducted an independent
risk assessment. Furthermore, the manufacturer must on this basis have prepared
operating instructions for the complete machinery/system.
These operating instructions do not serve as replacement of the operating
instructions of the overall machinery/system.
2.2 Intended use
The hydraulic power unit is a hydraulic system component.
You may use the product as follows:
The hydraulic power unit constitutes partly completed machinery in the sense of the
EC Machinery Directive 2006/42/EC and as such it is not ready for use.
The hydraulic power unit is intended exclusively for being integrated in a machine
or installation or for being assembled with other components to form a machine
or system. The product may be commissioned only if it has been integrated into
the machine or system for which it is designed and if the machine or system fully
complies with the requirements of the EC Machinery Directive.
The hydraulic power unit serves for controlled or regulated generation of hydraulic
flow and hydraulic pressure.
The hydraulic power unit is not considered to be a safety component in the sense
of the EC Machinery Directive 2006/42/EC.
The hydraulic power unit must not exceed the operating conditions and
performance limits specified in the technical data.
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The hydraulic power unit is technical equipment exclusively intended for
professional and not for private use.
Intended use also includes having read and understood this documentation
completely, especially chapter 2 "Safety instructions" and chapter 3 "General notes
on damage to property and damage to the product".
2.3 Improper use
Any use other than described in the section “Intended use” is considered as
improper and is therefore not permitted.
Bosch Rexroth AG does not assume any liability for damage caused by improper use.
The user assumes all risks involved with improper use.
The hydraulic power unit is not suitable for operation in explosive environments.
Improper use of the hydraulic power unit includes:
▶ Non-compliance with the technical data, operating conditions, performance limits
and environmental conditions specified in the data sheet.
▶ Operation of the hydraulic power unit with hydraulic fluid not complying with the
specifications in the data sheet.
▶ Use of spare parts that are not approved by the manufacturer.
▶ Mechanical modification of the hydraulic power unit.
▶ Welding or soldering work at the hydraulic power unit.
2.4 Qualification of personnel
The activities described in this documentation require basic knowledge of
mechanics, electrics and hydraulics as well as knowledge of the appropriate
technical terms. For transporting and handling the hydraulic power unit, additional
knowledge of how to handle lifting gear 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 respective field or an instructed person under the direction and
supervision of an expert.
Experts are those who are able to recognize potential hazards and apply the
appropriate safety measures due to their professional training, knowledge and
experience, as well as their understanding of the relevant requirements pertaining
to the work to be undertaken. An expert must observe the relevant specific
professional rules and have the necessary hydraulic and electrical expert knowledge.
Bosch Rexroth offers training courses that support your qualification in specific
fields. You can find an overview of training contents on the Internet at: https://
www.boschrexroth.com
2.5 General safety instructions
• Observe the valid regulations on accident prevention and environmental protection.
• Observe the safety regulations and provisions of the country in which the product
is used/applied.
• Exclusively use Rexroth products in technically perfect condition.
• Observe all notices on the product.
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• Persons who install, commission, operate, demount or maintain Rexroth products
must not consume any alcohol, drugs or pharmaceuticals that may affect their
ability to respond.
• Only use accessory and spare parts released by the manufacturer in order to rule
out personnel hazards arising from unsuitable spare parts.
• Comply with the technical data and ambient conditions specified in the product
documentation.
• If unsuitable products are installed or used in safety-relevant applications,
unintended operational states can occur in these applications, which can cause
personal injury and 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 product, e.g. in explosion protection zones or in safety-
related parts of control systems (functional safety).
• You may commission the product only when it has been established that the
final product (for example, a machine or system), in which the Rexroth product
is installed, complies with national regulations, safety regulations and standards
relevant for the application.
• Only persons who have been authorized by the machine end-user may be granted
access to the direct operating range of the machine/system. This also applies
during any standstill of the machine/system.
2.6 Product-specific safety instructions
WARNING
Pressurized hydraulic power unit, pressurized machine/system!
Danger to life and risk of serious injury when working on running machines/
systems, burns, environmental pollution, damage to property!
▶ Ensure that all relevant components of the hydraulic system are depressurized
and that the electrical control is de-energized. For doing so, observe the
specifications of the machine/system manufacturer and/or end-user.
▶ Do not disconnect line connections, ports or components as long as the
hydraulic system is pressurized.
▶ Make sure that appropriate safety measures are implemented to prevent
any dangerous situations for personnel and real assets if commissioning or
maintenance work requires decommissioning of safeguards like fuses, pressure
relief valves or covers (frequency converter).
▶ Make sure that all safeguards like fuses, pressure relief valves or covers
(frequency converter) of the hydraulic power unit are in place, properly installed
and functional on re-commissioning.
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WARNING
High electrical voltage!
Danger to life and risk of injury caused by electric shock!
▶ Make sure the relevant system part is de-energized when working on the system.
▶ Secure the system against restarting.
▶ Operate the hydraulic power unit only with a permanently installed protective
grounding conductor.
▶ Observe the discharge time (at least 30 minutes) of capacitors.
Leakage of (pressurized) hydraulic fluid and oil mist!
Danger to life! Risk of injury! Risk of explosion! Risk of fire! Environmental
pollution! Damage to property!
▶ Switch the system off immediately (emergency stop switch).
▶ Identify and eliminate the leakage.
▶ Never try to stop or seal the leakage or the oil jet with a cloth.
▶ Avoid direct contact with ejecting hydraulic fluid.
▶ Visually inspect the hydraulic power unit and oil-containing components for
leakage at regular intervals.
▶ Use your personal protective equipment.
▶ Keep open fire and ignition sources away from the hydraulic power unit.
▶ When dealing with hydraulic fluids, you must imperatively observe the notices of
the manufacturer.
▶ When carrying out welding work on the system make sure that the grounding
(electric welding circuit) is not lead via the hydraulic power unit.
Unexpected start-up due to malfunctions/incorrect operation!
Danger to life! Risk of injury!
▶ Ensure that the hydraulic power unit is secured against unexpected start-up.
▶ Regularly check the hardware and software.
▶ Make sure that required measures for decommissioning are implemented by the
machine manufacturer as the hydraulic power unit is not equipped with direct
measures (e.g. switches) for shutting the product down.
Direct contact with live components in case of fault, e.g. loose terminals,
insulation defects, missing grounding, malfunction of fuses or damaged lines,
components or terminals!
Danger to life! Risk of injury! Danger caused by electric shock or severe injury!
▶ Before carrying out any maintenance work, always de-energize the relevant
system part.
▶ Ensure continuous connection of the protective grounding conductor.
▶ Observe the operating conditions and performance limits specified in the
technical data.
▶ Work on electric equipment may only be performed by skilled electricians.
▶ Comply with the recommended inspection and maintenance intervals.
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WARNING
Overheating of the hydraulic power unit (electric motor, frequency converter,
hydraulic components and central plate) and pressure line!
Danger to life! Risk of injury! Risk of explosion!
▶ Disconnect the relevant system part immediately from the power supply.
▶ Correct the cause of overheating.
▶ Do not use the hydraulic power unit in potentially explosive atmospheres.
Functional restrictions of the hydraulic power unit due to electromagnetic
radiation!
Danger due to uncontrolled machine movements resulting from electromagnetic
radiation of unshielded connection cables.
▶ Observe the EMC limit values!
▶ Only use recommended electrical connection cables in accordance with
the EMC Directive and shield electronics from the source of disturbance as
required.
▶ Keep the recommended distance to the source of interference.
▶ Provide for proper, safe PE connection.
Overheating of electrical cables and components or short-circuit!
Danger to life! Risk of injury! Risk of fire!
▶ Observe the operating conditions and performance limits and safeguards
specified in the technical data.
CAUTION
Hot surfaces of the hydraulic power unit!
Risk of injury! Risk of burning!
▶ Allow the hydraulic power unit to cool down sufficiently before touching it.
▶ Wear heat-resistant gloves or protective clothing. During or after operation,
temperatures may rise to values higher than 60 °C, depending on the operating
conditions.
▶ Observe the protective measures of the machine/system manufacturer and/or
operator.
Leaked hydraulic fluid, oily surfaces!
Risk of injury! Risk of slipping.
▶ Secure and mark the danger zone.
▶ Immediately remove hydraulic fluid that has leaked out.
▶ Use an oil binding agent in order to bind spilled hydraulic fluid.
▶ Remove and dispose of the contaminated oil binding agent, see chapter 13
"Disposal".
▶ Wear the personal protective equipment prescribed for your activity.
▶ Perform a leak test.
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CAUTION
Contact with hydraulic fluid!
Health hazard/impairment of health, e.g. eye injuries, skin lesions, intoxication upon
inhalation or due to swallowing, sensitization!
▶ Avoid contact with hydraulic fluids.
▶ When handling hydraulic fluids, strictly observe the safety notes of the hydraulic
fluid manufacturer.
▶ Use personal protective equipment (e.g. safety goggles, protective gloves,
suitable workwear, safety shoes).
▶ If nevertheless hydraulic fluid comes into contact with the eyes or gets into the
bloodstream or is swallowed, consult a doctor immediately.
Electromagnetic and magnetic fields!
Health hazard for persons with cardiac pacemakers, metal implants or hearing aids!
▶ Make sure that above specified personnel are prevented from accessing areas
where drive components are installed and operated or arrange consultation with
a doctor for approval.
Sharp edges!
Risk of injury!
▶ Wear personal protective equipment.
Loud noise due to excessively high sound pressure level (in case of malfunction)!
Risk of hearing damage (temporary/permanent), stress/loss of attention! Fault in
voice communication and acoustic signals!
▶ Wear your hearing protection.
▶ Consult the machine manufacturer or Bosch Rexroth to identify any malfunction
if applicable.
2.7 Personal protective equipment
During operation and maintenance work as well as during installation and removal of
the hydraulic power unit, always wear the following personal protective equipment:
• Heat- or cold-resistant protective gloves
• Hearing protection
• Safety shoes
• Perfectly fitting safety goggles
• Protective helmet
2.8 Obligations of the machine end-user
In order to ensure safety when handling the hydraulic power unit and its
components, the machine end-user of the system must:
• guarantee the intended use of the hydraulic power unit and its components
according to chapter 2.2 "Intended use".
• instruct the operating personnel regularly in all aspects of the operating
instructions and make sure that they are observed.
• ensure compliance with the instructions on occupational safety and with the
operating instructions.
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• ensure compliance with operating data (admissible operating temperature,
maximum operating pressure).
The machine end-user of the Bosch Rexroth hydraulic power unit is obliged to
provide personnel training on a regular basis regarding the following subjects:
•Observation and use of the operating instructions as well as the legal regulations.
•Intended operation of the Bosch Rexroth product.
•Observation of the instructions of factory security officers and of the operating
instructions of the machine end-user.
• Behavior in case of emergency.
The operation of installations, systems and machines basically requires the
implementation of a holistic IT security concept which is state-of-the-art in terms
of technology. Accordingly, BoschRexroth products and their properties must be
considered as components of installations, systems and machines for their holistic IT
security concept.
Unless otherwise documented, BoschRexroth products are designed for operation
in local, physically and logically secured networks with access restrictions for
authorized persons, and they are not classified according to IEC62443-4-2.
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3 General notes on damage to property
and damage to the product
The warranty only applies to the delivered configuration. The warranty becomes
void if the product is incorrectly mounted, commissioned or operated, not used
as intended and/or handled improperly.
NOTICE
Danger due to improper handling!
Damage to property!
▶ You may only use the hydraulic power unit according to section 2.2 "Intended
use".
▶ Do not expose the hydraulic power unit to any mechanical loads under any
circumstances.
▶ Do not place/put any objects on top of the hydraulic power unit.
▶ Never use the hydraulic power unit as a handle or step.
▶ Do not apply any external loads on the hydraulic power unit.
Unauthorized changes to the frequency converter parameters!
Damage to property!
▶ Parameters may only be changed in accordance with commissioning instructions
RE 51055-IB.
▶ Coordinate any changes of other parameters with the Bosch Rexroth customer
service.
Operation with lack of hydraulic fluid!
Damage to property!
▶ When commissioning or re-commissioning a machine or system, make certain
that the oil tank as well as the suction and working lines of the hydraulic power
unit and the components are filled with hydraulic fluid and remain filled during
operation.
▶ Observe the machine/system manufacturer's specifications regarding the point
“Check of the hydraulic fluid" and the prescribed remedial measures for the
check result.
Leaking or spilled hydraulic fluid!
Environmental pollution and pollution of the ground water!
▶ Use an oil binding agent in order to bind spilled hydraulic fluid.
▶ When filling and draining the hydraulic fluid, always put a collecting pan under
the hydraulic power unit.
▶ Observe the information in the safety data sheet for the hydraulic fluid and the
instructions provided by the system manufacturer.
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NOTICE
Mixing of hydraulic fluids!
Damage to property!
▶ Any mixing of hydraulic fluids of different manufacturers and/or of different
grades of the same manufacturer is generally not admissible.
Contamination by fluids and foreign particles!
Premature wear and malfunctions!
Take the following measures to protect the hydraulic power unit:
▶ During mounting, provide for cleanliness in order to prevent foreign particles
e.g.welding beads or metal chips from getting into the hydraulic lines and
causing wear or malfunctions in the hydraulic power unit.
▶ Make sure that all connections, hydraulic lines and attachment parts
(e.g.measuring devices) are clean and free of chips.
▶ For removing lubricants or any other contamination, use industrial residue-free
wipes.
▶ Only carry out cleaning processes at the hydraulic power unit when the
hydraulic connections are plugged or connected.
▶ Before commissioning, ensure that all hydraulic and mechanical connections
have been made.
▶ Make sure that no contaminants penetrate when closing the measuring ports.
Improper cleaning!
Damage to property!
▶ Cover all openings with the appropriate protective plug screws in order to
prevent cleaning agents from penetrating the system.
▶ Check that all seals and electric plug-in connections are firmly fitted to prevent
the penetration of cleaning agents.
▶ Do not use aggressive cleaning agents for cleaning. Clean the hydraulic power
unit using a suitable cleaning liquid.
▶ Do not use high-pressure cleaners.
▶ Do not use compressed air for the cleaning at functional interfaces.
▶ Make sure that the cover is turned to "closed position" after cleaning. See also
fig. 1, left view.
Environmental pollution caused by incorrect disposal!
Environmental pollution! Damage to property!
▶ Dispose of the hydraulic power unit, the hydraulic fluid and the packaging in
accordance with the applicable national regulations in your country.
▶ Dispose of the hydraulic fluid according to the applicable safety data sheet of
the hydraulic fluid.
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4 Scope of delivery
The following is included in the scope of delivery:
• Hydraulic power unit CytroPac
• Operating instructions (this document) including EC declaration of incorporation
For further information on optional components, refer to chapter 17.4
"Accessories".
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5 About this product
5.1 Performance description
The CytroPac is a compact drive system (smaller tank, cooling system) for hydraulic
machines and particularly machine tools and assembly lines with limited installation
space conditions.
The CytroPac is particularly quiet due to plastic enclosure of all noise sources.
The frequency converter of the variable-speed pump drive ensures dynamic
adjustment of the power/speed and thus of the flow to current requirements to
reduce the operating costs.
In the "Basic" configuration, the fill level, temperature and filter clogging sensors
must be wired by the customer and evaluated via the customer-side machine control.
In the "Advanced" configuration, the frequency converter serves as sensor node and
bundles all measured values of fill level, temperature and filter clogging sensors and
forwards these values via a mating connector to the customer-side machine control.
The status of the hydraulic power unit is also indicated via the integrated LED strip.
Information on the meaning of the LED signals can be found in chapter 10.3
“Warning devices“ on page52 .
In the "Premium" configuration, the frequency converter serves as sensor node and
bundles all measured values of fill level, temperature and filter clogging sensors and
forwards these values via a multi-Ethernet interface, e.g. Sercos or PROFINET, to
the machine control. This ensures reading of all parameters required for condition
monitoring. The CytroPac can be easily integrated in Industry 4.0 applications. The
status of the hydraulic power unit is also indicated via the integrated LED strip.
Information on the meaning of the LED signals can be found in chapter 10.3
“Warning devices“ on page 52.
For an overview of components of the various configurations, refer to data sheet
51055, section “Sensor and interface selection", see chapter 1.2 "Required and
supplementary documentation".
In the "Premium" configuration, the pressure command value can be changed via the
higher-level machine control system during runtime. The new settings are
automatically and independently implemented by the hydraulic power unit via the
frequency converter.
In the "Advanced" and "Premium" configurations, all sensors and the motor in the
hydraulic power unit are wired to the frequency converter. For this reason, only the
following interfaces are required at the hydraulic power unit:
• Interface for feed-in/voltage supply (12X1)
• Interface for enable signal 24VDC (15X1)
Fields of application
Low noise level
Cost-effective operation
Various extension stages
Parameter adjustment
during runtime
Space-saving installation
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• Hydraulic connection/oil drain
• Connection to the cooling water supply
• Multi-Ethernet interface ("Premium" only, 21X1, 21X2)
The product provides the following features which are relevant for the CytroPac:
• Pressure/flow setting
– Easy command value setting (internal command values, and 4 switchable
parameters for pressure command value)
– Command value setting possibility via communication (Premium CytroPac only)
• p/Q PID-control
– p/Q control with automatic switching between pressure and flow control modes
– Flow control
– Pressure control
– Two switchable controller parameter sets
• Extension functions
– Hydraulic soft start and separate acceleration ramp
– Sleep/wake-up function
– Pressure drop/overshoot compensation
– Power limitation of pump
– Master/slave control (Premium CytroPac only)
• Protective function
– Actual pressure monitoring
– Limit value for pressure and flow command value
– Oil change warning/error
– Thermal monitoring of pump
– CytroPac sensor monitoring (Advanced and Premium CytroPac only)
– LED blinking pattern showing converter status (Advanced and Premium CytroPac
only)
5.2 Product description
The CytroPac is a frequency-controlled hydraulic power unit consisting of a
frequency converter, electric motor, hydraulic pump, oil tank, cooling system
and sensorics. The cooling system consists of the heat exchanger for motor and
frequency converter cooling as well as optional cooling packages for hydraulic fluid
cooling.
The cooling power can be selected by the number of cooling packages in the oil tank
according to data sheet 51055. Refer to chapter 1.2 "Required and supplementary
documentation".
Thanks to the flow-optimized design of the oil tank, the required hydraulic fluid
volume was reduced to 20liters. The cooling system integrated in the oil tank
extracts heat energy from the hydraulic fluid and transfers it to the cooling water.
The ring-shaped oil tank includes the motor-pump group and additionally reduces the
operating noise.
The hydraulic power unit serves for the controlled or regulated generation of
hydraulic flow and hydraulic pressure.
Additional functions
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