Bosch Rexroth VT-PDFE-1X Series Bedienungsanleitung

Operating instructions

RE 29689-B/11.2019

Replaces: 01.2003

English

Test device for control system

SY(H)DFEE

Type VT-PDFE-1X...

The data speciﬁed only serve to describe

the product. If information on the use of the

product is given, it is only to be regarded as

application examples and recommendations.

Catalog information does not constitute

warranted properties. The information given

does not release the user from the obligation

of own judgment and veriﬁcation. Our

products are subject to a natural process of

wear and aging.

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.

RE 29689-B/11.2019; VT-PDFE-1X..., Bosch Rexroth AG

3/32Content

Content

1 About this documentation 5

1.1 Validity of the documentation 5

1.2 Required and supplementary documentation 5

1.3 Representation of information 5

2 Safety instructions 7

2.1 About this chapter 7

2.2 Intended use 7

2.3 Improper use 7

2.4 Qualiﬁcation of personnel 7

2.5 General safety instructions 8

2.6 Product-speciﬁc safety instructions 9

2.7 Safety equipment 12

2.8 Personal protective equipment 12

3 General information on damage to property anddamage to the product 13

4 Scope of delivery 14

5 About this product 14

5.1 Performance description 14

5.2 Product description 15

5.3 Identiﬁcation of the product 20

6 Transport and storage 20

7 Installation 21

7.1 Unpacking 21

7.2 Installation conditions 21

7.3 Required tools 21

7.4 Before use 21

7.5 Place of use 21

7.6 Installing the test device for SY(H)DFEE systems 22

8 Commissioning 24

8.1 Initial commissioning 24

9 Operation 24

10 Maintenance and repair 24

10.1 Cleaning and care 25

10.2 Repair 25

10.3 Spare parts 25

11 Demounting and replacement 26

11.1 Required tools 26

11.2 Preparing demounting 26

11.3 Preparations for storage and further use 26

12 Disposal 26

12.1 Environmental protection 26

12.2 Return to Bosch Rexroth AG 27

12.3 Packaging 27

12.4 Materials used 27

12.5 Recycling 27

13 Extension and modiﬁcation 27

14 Troubleshooting 28

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Bosch Rexroth AG, VT-PDFE-1X...; RE 29689-B/11.2019

14.1 How to proceed for troubleshooting 28

15 Technical data 28

16 Annex 29

16.1 List of addresses 29

17 Alphabetical index 30

About this documentation 5/32

RE 29689-B/11.2019; VT-PDFE-1X..., Bosch Rexroth AG

1 About this documentation

1.1 Validity of the documentation

This documentation is valid for the test device VT-PDFE-1-1X/V0/0, Mat. no.

R900757051.

This documentation is intended for ﬁtters, operators, service technicians and plant

operators.

This documentation contains important information on the safe and appropriate

installation, transport, commissioning, operation, use, maintenance, and removal

of the product.

▶ Read this documentation thoroughly and in particular chapter 2 “Safety

instructions“ and chapter 3 “General information on damage to property

anddamage to the product“, before working with the product.

1.2 Required and supplementary documentation

▶ Only commission the product, when you have the data sheet marked with

the book symbol at hand and when you have read and understood the

documentation of the valve that you wish to test or commission.

Bosch Rexroth data sheets and operating instructions are available online at www.

boschrexroth.com by entering the type code in the search function.

Table 1: Required and supplementary documentation

1.3 Representation of information

In order to allow you to work directly and safely with the test device described,

standardized safety notes, symbols, terms and abbreviations are used in this

documentation. For a better understanding, they are explained in the following

sections.

1.3.1 Safety instructions

In this documentation, safety instructions are included in chapter2.6 “Product-

speciﬁc safety instructions“ and in chapter3 “General information on damage

to property anddamage to the product“ and whenever sequences of actions or

instructions are explained which bear the risk of personal injury or damage to

property. The described hazard avoidance measures must always be observed.

Title Document number Document type

Proportional directional valves, direct operated, with electrical position feedback

as pilot control valve for control systems SY(H)DFE., Type VT-DFP.

29016 Data sheet

Pressure and ﬂow control system, SYDFEE series 2X, 3X, SYHDFEE series 1X 30012-B Operating

instructions

Variable-speed pressure and ﬂow control system Sytronix DFEn 5000, Type

SYHDFEn, type SYDFEn

20014-B Operating

instructions

SYDFED series 2X, 3X, SYHDFED series 1X, Pressure and ﬂow control system 30017-B Operating

instructions

6/32 About this documentation

Bosch Rexroth AG, VT-PDFE-1X...; RE 29689-B/11.2019

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-observance

•Precaution: speciﬁes how the hazardous situation can be prevented

Table 2: Hazard Classiﬁcations according to ANSI Z535.6-2011

Warning sign, signal word Meaning

DANGER Indicates a hazardous situation which, if not avoided, will

certainly result in death or serious injury.

WARNING Indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

NOTICE Damage to property: The product or the environment could

be damaged.

1.3.2 Symbols

The following symbols indicate notices which are not safety-relevant but increase

the comprehensibility of the documentation.

Table 3: Meaning of the symbols

Symbol Meaning

If this information is disregarded, the product cannot be used or operated

in an optimum manner.

▶ Individual, independent action

Numbered instruction:

The numbers indicate that the actions must be carried out one after the

other.

1.3.3 Designations

The following terms are used in this documentation:

Table 4: Designations

Designation Meaning

DFE system Pump control system with integrated electronics

Test device Device included in the scope of delivery for testing SY(H)DFEE control

systems

RE xxxxx Rexroth document in English language

Safety instructions 7/32

RE 29689-B/11.2019; VT-PDFE-1X..., Bosch Rexroth AG

2 Safety instructions

2.1 About this chapter

The test device described in the following has been manufactured according to

good engineering practice. However, there is still a risk of personal injury and/or

damage to property if you do not observe this chapter and the safety instructions

in this documentation.

▶ Read this documentation completely and thoroughly before working with the

product.

▶ Keep this documentation in a location where it is accessible to all users at all

times.

▶ Always include the required documentation when you pass the service case

with the test device on to third parties.

2.2 Intended use

The test device is suitable for activating and functional testing of Bosch Rexroth

SY(H)DFEx systems with integrated electronics and 11+PE connection.

The technical data of the device have to be observed without exception, and the

speciﬁed ambient conditions have to be adhered to, see chapter 15 “Technical

data“ on page 28.

The use in potentially explosive atmospheres is not permitted.

The device is provided for temporary use in a controlled electromagnetic

environment (according to EN 61326-1, table 3, testing according to EN 61326-

2-1) on hydraulic industrial equipment for commissioning, analyzing, testing and

servicing of hydraulic valves in plant.

Dry and clean ambient conditions have to be ensured.

2.3 Improper use

Any use other than described in the section “Intended use” is considered as

improper and is therefore not permitted und renders any warranty claims null and

void. It is also regarded as improper use if the test device is operated outside the

indicated performance limits and operating conditions, especially the prescribed

ambient conditions.

The test device is not provided for use in Class B environments (domestic/

residential). Should the test device nevertheless be used in a domestic/residential,

controlled electromagnetic environment (emission limit values of class B), further

measures have to be taken to prevent electromagnetic interference.

Bosch Rexroth AG does not assume any liability for damage caused by improper

use. The user assumes all risks involved with improper use.

2.4 Qualiﬁcation of personnel

The activities described in this documentation require basic knowledge of

electrical installation, control technology, programming and hydraulics as well

as knowledge of the appropriate technical terms. In order to ensure safe use,

these activities may only be carried out by an expert in the respective ﬁeld or an

instructed person under the direction and supervision of an expert.

8/32 Safety instructions

Bosch Rexroth AG, VT-PDFE-1X...; RE 29689-B/11.2019

Experts are those who are able to recognize potential hazards and apply the

appropriate safety measures due to their professional training, knowledge and

experience, as well as their understanding of the relevant requirements pertaining

to the work to be undertaken. An expert must observe the relevant speciﬁc

professional rules and have the necessary hydraulic expert knowledge.

Expert knowledge means, amongst others:

• the ability to read and completely understand circuit diagrams,

• in particular, completely understanding the correlations regarding safety

equipment and

• knowledge of the function and structure of hydraulic components,

• knowledge of the function and structure of electrical systems and components.

When working with the test device on a system/machine, it is advantageous if

the work is carried out by a specialist who is familiar with the system!

It is assumed that the device is used by trained and professional personnel in a

controlled electromagnetic environment to ensure proper usage.

Bosch Rexroth offers training courses that support your qualiﬁcation in speciﬁc

ﬁelds. You can ﬁnd an overview of training contents on the Internet at:

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.

• Persons who install, commission, operate, demount or maintain Rexroth products

must not consume any alcohol, drugs or pharmaceuticals that may affect their

ability to respond.

• Only use genuine Rexroth accessories and spare parts in order to exclude any

hazard to persons due to unsuitable spare parts.

• Comply with the technical data and ambient conditions speciﬁed in the product

documentation.

• The installation or use of inappropriate products in safety-relevant applications

could result in unintended operating states in the application which in turn could

cause personal injuries and/or damage to property.

• Do not commission the product until you can be sure that the end product (for

example a machine/system) where the Rexroth products are installed comply

with the country-speciﬁc provisions, safety regulations and standards of the

application.

• Please observe the safety-relevant information and risk speciﬁcations in the

operating instructions of the manufacturer of the connected hydraulic system

before commissioning the control with a hydraulic system.

Safety instructions 9/32

RE 29689-B/11.2019; VT-PDFE-1X..., Bosch Rexroth AG

• Please observe the general installation and safety regulations when working on

electrical systems.

• The information given in the product documentation with regard to the

use of the supplied components represents only application examples and

recommendations. The user has to check the suitability of the supplied device

and the information given in this documentation with regard to its use self-

dependently for his individual application as well as the compliance with the

safety regulations and standards valid for his application, and carry out the

required measures, changes and amendments.

• Technical data as well as connection and installation conditions are available in

the product documentation and have to be imperatively observed.

• In case of faults impairing the safety and changes in the operating behavior,

shut down the test device immediately and report the faults to the responsible

personnel.

• Generally, you must not modify or convert the product.

2.6 Product-speciﬁc safety instructions

WARNING

No functional safety!

Electronic pump systems provide machines or systems with hydraulic pressure.

In the case of mechanical and electrical faults, e.g. failure of the power supply,

persons may get caught, hurled or crushed by the installation.

▶ When using the test device in a system/machine make sure that it will not

make the functional safety of the system/machine ineffective or affect it in

whatever way!

Non-observance of control signals on the system side!

If control-side safety precautions are provided, they will be rendered ineffective.

▶ The test device may be used exclusively by personnel who are familiar with the

device, the valve and the hydraulic system. No liability is accepted for damage

caused by operating errors.

10/32 Safety instructions

Bosch Rexroth AG, VT-PDFE-1X...; RE 29689-B/11.2019

WARNING

Hazardous movements!

It is not allowed for persons to stay within the range of motion of the machines,

in which the test device is to be used. The following are examples of possible

measures against unintended access of persons:

• Protective fences

• Protective grids

• Protective covers

• Warning signs, barrier tapes

▶ If persons have to enter the hazard zone while the control is active, provide

superordinate monitoring functions on the system side or measures for

personal safety. These measures must be provided according to the speciﬁc

data of the system and on the basis of the risk and error analysis of the system

manufacturer/user. In this connection, the safety provisions applied for the

system must be taken into account.

▶ In case of faults impairing the safety and changes in the operating behavior,

shut down the test device and the valve immediately and report the faults to

the responsible personnel.

System parts under pressure and ejecting hydraulic ﬂuid!

When working on hydraulic systems with stored pressure energy (accumulator

or cylinders working under gravity), valves may even be pressurized after the

pressure supply has been switched off. During installation and demounting, the

valves or parts may be hurled around and cause personal injuries and/or damage

to property. There is moreover the risk of serious injury caused by a powerful,

ejecting hydraulic ﬂuid jet.

▶ Before installing the test device in the hydraulic system, ensure that the

hydraulic system is depressurized and the electrical control de-energized.

▶ Completely depressurize machines and systems before working on hydraulic

products.

Improper mounting or placement!

The test device is a mobile device, which is not provided for ﬁrm installation in

the system/machine. While being used, the device is connected to the measuring

line and is placed loosely in/on the system.

▶ Place the device so that it cannot fall down.

▶ Place the device so that no one can step on it.

▶ Make sure that the measuring line does not pose a risk of stumbling for third

parties or the operator himself/herself.

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