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Bosch rexroth CytroBox Operating Instructions Manual
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Bosch rexroth CytroBox Operating Instructions Manual

Hydraulic power unit
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Hydraulic power unit
CytroBox
Operating instructions
RE 51057-B/11.19
Replaces: –.–
English

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Summary of Contents for Bosch rexroth CytroBox

  • Page 1 Hydraulic power unit CytroBox Operating instructions Replaces: –.– RE 51057-B/11.19 English...
  • Page 2 Please note that our products are subject to a natural process of wear and aging. © All rights are reserved to Bosch Rexroth AG, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.

  • Page 3: Table Of Contents

    6.1.3 Transport using lifting gear Storage of the hydraulic power unit Assembly Unpacking the hydraulic power unit Installing the hydraulic power unit 7.2.1 Dimensions of the hydraulic power unit (dimensions in mm) Hydraulic supply connection CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 4 10.5.8 Visual inspection for leakage, cracking, force effects and corrosion 10.6 Spare and wear parts Decommissioning 11.1 Preparing for decommissioning 11.2 Decommissioning process Disassembly and replacement 12.1 Preparing disassembly 12.2 Disassembly process Disposal 13.1 Environmental protection Extension and modification Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 5 How to proceed for troubleshooting 15.1.1 Overview of the impact of defects Technical data Appendix 17.1 List of addresses 17.2 Declaration of incorporation 17.3 Prohibited substances - REACH, RoHS, WEEE 17.4 Accessories Alphabetical index CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 6 6/128 Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 7: About This Documentation

    Environmentally compatible hydraulic fluids 90221 Data sheet Includes application notes and requirements for Rexroth hydraulic components. Sytronix, SvP 7020 IMC, variable-speed pump drives R911376148 Description of the Includes a description how to commission SvP 7020 IMC. commissioning CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 8 This documentation explains the commissioning of drive controllers of the instruction following drive families: IndraDrive C, IndraDrive M, IndraDrive Mi and IndraDrive Cs with EtherCAT communication in connection with the external control TwinCAT by Beckhoff. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 9: Representation Of Information

    WARNING severe injury if not avoided. Indicates a dangerous situation which may cause minor or CAUTION medium (personal) injury if not avoided. Damage to property: The product or the environment could NOTICE be damaged. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 10: Symbols

    Registration, Evaluation, Authorization and Restriction of Chemicals RoHS Restriction of (the use of certain) Hazardous Substances in electrical and electronic equipment SERCOS Safe Torque Off SVHC Substances of Very High Concern WEEE Waste of Electrical and Electronic Equipment Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 11: Safety Instructions

    The hydraulic power unit must not exceed the operating conditions and performance limits specified in the technical data. The hydraulic power unit is technical equipment exclusively intended for professional and not for private use. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 12: Improper Use

    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 improper use. The user assumes all risks involved with improper use. The hydraulic power unit is not suitable for operation in explosive environments.

  • Page 13: General Safety Instructions

    • 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. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 14: Product-Specific Safety Instructions

    When dealing with hydraulic fluids, you must imperatively observe the notices of the manufacturer. ▶ Make sure that the grounding (electric welding circuit) during welding works at the system is not lead via the hydraulic power unit. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 15 Provide for proper, safe PE connection. Overheating of electric lines 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. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 16 Fault in voice communication and acoustic signals! ▶ Wear your ear protection. ▶ Consult the machine manufacturer or Bosch Rexroth to identify any malfunction if applicable. ▶ Make sure that during operation, all doors are closed. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 17: Personal Protective Equipment

    • 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.

  • Page 18: General Information On Damage To Property And Damage To Product

    Only change the parameters specified in chapter 8.1.8 "Commissioning of the "electronics"" according to your application and system requirements. ▶ Coordinate the any changes of other parameters with the Bosch Rexroth customer service. Operation with lack of hydraulic fluid! Damage to property! ▶...
  • Page 19 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. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 20: Scope Of Delivery

    • Mating connector for port 21X1 • Network cable for port 22X1 • Connector plug for filling coupling For required and amending documentation, refer to chapter 1.2. For further information on optional components, refer to chapter 17.4 "Accessories". Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 21: Product Information

    Optionally, the hydraulic fluid is cooled by a circulation circuit with a plate heat exchanger. The hydraulic power unit requires a cooling water connection. The oil temperature can be set by means of parameters. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 22 5.3.1 "Drive controller". Optionally, the following components are available: Optionally available • Hydraulic control, type IH20 • Accumulator station • Customer-specific hydraulic control Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 23: Product Description

    The system conditions are indicated by means of the integrated LED status display, see Fig. 5, pos. 3 on page 48 and on the display of the drive controller, see Fig. 1 on page 24 and Fig. 7 , pos. 16 on page 50. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 24: Functional Description

    Fig. 1: Operating unit with 8-digit display (standard display) A detailed functional description of the operating unit is provided in the application description "IndraDrive, MPx-20, functions", see chapter 1.2 "Required and amending documentation". Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 25 Further operating conditions and information on the operation of the display are provided in the help function of IndraWorks DS. Press the enter key to jump to a subordinate menu. Fig. 2: Example: Display of IP addresses CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 26 X26 (in the electrical cabinet of the CytroBox). The connection to the PC can be established by a standard RJ45 Ethernet cable. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 27: Sensor Evaluation

    Error too low °C P-0-1389[28] Error too low °C P-0-1291 Actual value liters P-0-1311[160] Min. liters P-0-1311[161] Max. liters P-0-1311[162] Min. P-0-1311[163] Max. P-0-1389[71] Min. liters P-0-1389[72] Max. liters P-0-1389[73] Min. liters P-0-1389[74] Max. liters CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 28 Table 8: Parameters for dissolved air inclusion Function Parameter Description Unit Bytes Decimal Default points P-0-1270 Actual value mbar P-0-1311[165] Min. mbar P-0-1311[166] Max. mbar P-0-1311[167] Signal min. mbar P-0-1311[168] Signal max. mbar P-0-1389[7] Warning mbar P-0-1389[8] Error mbar Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 29 Actual value (L) P-0-1389[63] Warning P-0-1389[67] Error P-0-1427 Actual value (XL) P-0-1389[64] Warning P-0-1389[68] Error P-0-1311[170] Min. P-0-1311[171] Max. P-0-1311[172] Min. P-0-1311[173] Max. P-0-1311[176] Starting signal P-0-1311[177] Starting signal 3400 P-0-1311[178] Delay 3500 P-0-1311[179] Cycle 4000 CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 30 Relative oil humidity is output in P-0-1272. The measured temperature value of the sensor is not used. Table 10: Parameters for relative oil humidity Function Parameter Description Unit Bytes Decimal Default points P-0-1272 Actual value P-0-1389[13] Warning P-0-1389[14] Error P-0-1389[15] Debouncing time Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 31 Optional scope of delivery) Pressure sensor Filling level sensor Temperature sensor Pressure filter contamination sensor Leakage flow sensor Leakage temperature sensor Water content sensor Air inclusion sensor Dirt particle sensor Drip pan leakage sensor CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 32: Monitoring Systems

    The monitoring is based on a cycle time of 1 ms. Table 15: Leakage flow monitoring Message Threshold value Debouncing Diagnostic Bit in status word [l/min] time [ms] number (P-0-1412/P-0-1413) Warning P-0-1389[39] B318 P-0-1389[38] Error P-0-1389[40] D318 Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 33 Error M - 6 µm P-0-1389[66] D303 Warning L - 14 µm P-0-1389[63] B304 Error L - 14 µm P-0-1389[67] D304 Warning XL - 21 µm P-0-1389[64] B305 Error XL - 21 µm P-0-1389[68] D305 CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 34 The monitoring is based on a cycle time of 200 ms. Table 22: Fluid detection Message Threshold value Debouncing Diagnostic Bit in status word time [ms] number (P-0-1412/P-0-1413) P-0-1389[42] B329 Warning Oil P-0-1389[41] Warning Mixture P-0-1389[43] B330 Warning Water P-0-1389[44] B331 Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 35: Fixed Command Value Memory

    Table 24: P-0-1401 service mode P-0-1401 bit Function level Service mode selection FALSE = commanding p and n from cyclic customer interface for IMC TRUE = commanding p from P-0-1403 and n from P-0-1404 CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 36 The operating points for pressure p and speed n can be configured in the following parameters: Table 27: Configuration of the operating points Operating point Operating point index Pressure p Speed n P-0-1311[100] P-0-1311[110] P-0-1311[101] P-0-1311[111] P-0-1311[112] P-0-1311[102] P-0-1311[103] P-0-1311[113] Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 37: Oil And Water Cooling

    (P-0-1389 [20]), cooling is stopped. Table 30: Control of water cooling valve P-0-1418 Description Bit 6 FALSE Valve for water cooling closed TRUE Valve for water cooling open CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 38: Degassing And Drainage

    The degassing and drainage function is deactivated on delivery. Due to complex interactions with the complete hydraulic system, these functions can only be activated and parameterized in cooperation with Bosch Rexroth. Degassing and drainage of oil is provided. For this purpose, the air and water...

  • Page 39: Rgb Led As Status Display

    Drive warning Nothing amiss – Cyan neither error nor warning 5.3.8 Description of parameters and diagnosis The following chapter includes a list of all available parameters as well as all occurring errors and warnings. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 40 Warning P-0-1389[67] Error Particle P-0-1427 Actual value (XL) concentration P-0-1389[64] Warning P-0-1389[68] Error P-0-1311[170] Min. P-0-1311[171] Max. Standardization P-0-1311[172] Min. P-0-1311[173] Max. P-0-1311[176] Starting signal P-0-1311[177] Starting signal Threshold value P-0-1311[178] Delay P-0-1311[179] Cycle Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 41 P-0-1389[68] Error XL - 21 µm P-0-1389[7] Warning Threshold value Dissolved air P-0-1389[8] Error inclusion P-0-1389[9] Debouncing time P-0-1389[12] Activation of drainage Threshold value P-0-1389[13] Warning Relative oil humidity P-0-1389[14] Error P-0-1389[15] Debouncing time CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 42 P-0-1380 Bit 1 TRUE Drainage activated Disabled Valve for degassing closed Degassing P-0-1418 Bit 0 Enabled Valve for degassing open Not activated Valve for drainage closed Drainage P-0-1418 Bit 1 Activated Valve for drainage open Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 43 Check the limit values. very low run (P-0-1270 > P-0-1389[2]) but ▶ Perform a pressure control with a higher the oil system pressure is too command value. low (S-0-0813 < P-0-1389[3]). ▶ Check the sensor output signal. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 44 Remove the faulty sensor. sensor. ▶ Check the connection of the oxygen sensor • An incorrect sensor on the basis of the electrical circuit diagram. (vendor/device ID) is connected to IO link port 3. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 45 IO link gateway is wrong. ▶ Check the device description itself. • The device description file ▶ Use the supplied device description file with used for the IO link gateway is the correct configuration. wrong. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 46 D318: leakage very The monitoring of the leakage ▶ Check the limit value. high flow indicates an alarm. ▶ Check the sensor output signal. P-0-1293 > P-0-1389[40] ▶ Check the pump and replace it, if necessary. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 47 D700: user config The configuration of the device ▶ Check the editable inputs (for details see text). input err, P-0-1389 (...) data (e.g. threshold value) ▶ Reset the configuration to factory settings. cannot be implemented. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 48: Component Overview

    11 Cooling water connections 5 Air inlet at the electrical cabinet (push-in, d =12 mm) 6 Adjustable machine feet 12 Air inlet at the hydraulic cabinet 7 Foundation made of polymer concrete 13 Drip pan discharge plate Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 49 3 Filling level and temperature sensor 9 Degassing and drainage module 4 Pressure port P, G1 1/4 10 Oil tank port G1 1/2 (backup) 5 Manifold block 11 Breathing filter 6 Return flow port T, G1 1/2 CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 50 17 Micro SD card 8 Fuse for 24-V-power supply unit 18 Mains filter 9 Protective motor switch for 19 Power contactor circulating pump 20 24-V-power supply unit 10 Protective motor switch for air cooler 21 Mains throttle Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 51 4 Return line 12 Pressure line 5 Pressure relief valve 13 Suction line 6 Dirt particle sensor (optional) 14 Water content sensor (optional) 7 Optical oil level indicator 15 Filling coupling 8 MS2N motor CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 52: Circuit Diagram, Hydraulic

    52/128 Product information 5.5 Circuit diagram, hydraulic Fig. 9: Circuit diagram, hydraulic Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 53 Pressure relief valve DBDS 20 K1X/315 7.030 Pressure filter 550PMFAN0250-PWR10B00-M 7.040 Check valve M-SR 25 KE05-1X/ 7.050 Pressure sensor HM 20-2X/400-C-K35-N 7.060 Pressure sensor HM 20-2X/400-C-K35-N 7.070 Measuring coupling MCS20-SDS-E-G1/4-ST3N00Z-M 7.080 Measuring coupling MCS20-SDS-E-G1/4-ST3N00Z-M 7.090 Measuring coupling MCS20-SDS-E-G1/4-ST3N00Z-M CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 54: Product Identification

    54/128 Product information 54/128 5.6 Product identification The hydraulic power unit can be identified by its name plate. The following figure shows an exemplary representation: Fig. 10: Example: name plate Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 55: Transport And Storage

    Use a forklift or suitable lifting gear e.g. lifting slings or lifting straps to transport the hydraulic power unit. ▶ During transport, secure the hydraulic power unit against falling. ▶ Carefully position the hydraulic power unit on the contact surface to prevent any damage. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 56: Preparing For Transport

    Avoid jerky acceleration and deceleration forces. The total weight of the hydraulic power unit varies depending on the version and customer-specific extension. Lifting using eyebolts is admissible up to a maximum total weight of 800 kg. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 57 Slowly and carefully lift the hydraulic power unit in order to avoid swinging. Fig. 12: Eyebolts When attaching the lifting gear, make sure the angle is correct, see DIN 580 (ring bolts) and DIN 818-4 (chains). CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 58: Storage Of The Hydraulic Power Unit

    If the storage time exceeds 12 months, check the function of the hydraulic power unit and flush it with suitable cleaning liquid prior to commissioning. Carry out the flushing procedure as described in chapter 8.1.6 "Flushing the hydraulic system". Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 59: Assembly

    To install the hydraulic power unit, you should proceed as follows: ▶ Put the hydraulic power unit on a level ground. ▶ Level the hydraulic power unit using the adjustable machine feet so that its longitudinal and transverse axis are horizontal. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 60: Dimensions Of The Hydraulic Power Unit (Dimensions In Mm)

    60/128 Assembly 7.2.1 Dimensions of the hydraulic power unit (dimensions in mm) Wout Wout Fig. 13: Dimensions of the hydraulic power unit Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 61: Hydraulic Supply Connection

    ▶ Observe the installation information of the fitting manufacturers to prevent any external leakage. Bosch Rexroth recommends fittings with elastic seals. Hose lines Install the hose lines in such a way that – kinking and tensile load at the hose is prevented during operation.
  • Page 62 The pressure relief valve is completely opened on delivery and must be set during commissioning. For further information on setting the pressure relief valve, please refer to chapter 8.1.5 "Commissioning of the "hydraulics"" on page 73. Fig. 15: Pressure relief valve 1 Pressure relief valve Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 63 The Minimess connection MP3 (see Fig. 9, pos. 7.070 on page 52) is used to determine the actual operating pressure or to bleed the system if there is no control system. ▶ Close unused ports with blanking plugs. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 64: Water Supply Connection

    Fig. 17, pos 1 and 2. connectors (standard) This will cool the electric motor and the hydraulic fluid, if any. Fig. 17: Cooling water connections 1 Push-in cooling water connection 2 Push-in cooling water connection (input) (output) Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 65: Electrical Interface Assignment

    Voltage (according to IEC 60038) 400 … 500 VAC (+10 % / -15 %) Frequency 50/60 Hz Fuse for the supply line, customer-side Converter HCS03 - 0070: maximum 50 A Converter HCS03 - 0100: maximum 80 A Converter HCS03 - 0150: maximum 125 A CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 66: Interface 20X1 Assignment: Digital Input And Output Signals

    Ready for operation, no error M 12x1; 8-pole A - coded In operation *) Input DI/output DO Inputs: 24 VDC (high ≥ 11 V; low ≤ 5 V) Outputs: max. current 500 mA; total of all currents max. 2000 mA Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 67: Interface 21X1 Assignment: Safe Torque Off (Sto)

    "Rexroth IndraDrive, integrated safety technology "Safe Torque Off" (from Mpx-16)", see chapter 1.2 "Required and amending documentation". Application examples STO function Fig. 18: With two-channel wiring and passive safety unit The dynamization signals can be freely assigned. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 68: Interfaces 22X1 And 22X2: Multi-Ethernet Control Communication As Well As 30X1: Cytroconnect

    If you wish to use the CytroConnect service via this connection type, please contact us at the following e-mail address: Consult-and-Connect@boschrexroth.de ▶ Connect the CytroConnect connection 30X1 to the company network using a corresponding RJ45 line connector. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 69: Interface 23X2 Assignment: Connection Of Cooling Unit And 23X3: Water Valve Connection (Optional)

    Reading or configuration of parameters or reading of errors can be realized via the engineering port X26, see Fig. 7, pos. 15 on page 50, and by means of the software IndraWorks DS. ▶ Use an appropriate standard RJ45 connector for the X26 port. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 70: Electrical Interface Connection

    3 23X3: Water valve control (optional) 4 Mobile communications antenna 5 22X1: Multi-Ethernet control communication (network output) 6 22X2: Multi-Ethernet control communication (network input) 7 30X1: CytroConnect 8 23X2: Cooling unit control (optional) 9 Cable bushing for power supply Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 71: Commissioning

    The optional tank volume of the CytroBox is 100 to 130 liters and can be checked via the oil level indicator, see Fig. 21, pos. 1. ▶ Make sure that the maximum filling pressure does not exceed 2 bar. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 72 If you want to ensure the cleanliness class, carry out the filling of the hydraulic power unit using a special filling unit, if necessary, or use a filter station with a 10 µm fine filter. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 73: Switching On The Power Supply

    Operate the directional valves and extend and retract the actuators several times. ▶ Repeat the bleeding process. Bleeding is ensured if no foaming of hydraulic fluid in the oil tank, no jerky motions at the actuator and no irregular noise occur. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 74 25402-B, see chapter 1.2 "Required and amending documentation". To support systematic inspection for and reduction of errors, refer to the matrix, Problems during see Table 51 "Impact of defects" in chapter 15 "Troubleshooting". commissioning Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 75: Flushing The Hydraulic System

    The following instructions refer to flushing with the hydraulic power unit described in these operating instructions. For use of a separate flushing unit, the respective operating instructions must be observed! CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 76: Common Errors During Commissioning

    No general statement can be made on the duration of the flushing process. Flushing time As per Bosch Rexroth recommendation, regular hydraulic fluid samples should be taken during flushing and analyzed for cleanliness. A suitable sampling point is the return line upstream of the return flow filter.

  • Page 77: Commissioning Of The "Electronics

    IP and computer configuration. You will also find devices with IP configurations beyond the sub-network used. However, this requires a fixed IP address set on the PC or notebook (no DHCP). A search across network boundaries (router) is not possible. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 78 Fig. 7, pos. 16 on page 50 of the indicated drive. If the network search was successful but the IP address does not match, communication is not possible. IndraWorks then displays the device in red. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 79 The address is automatically deleted if the checkbox for "Restore old settings on exit" is selected and IndraWorks is closed, or after a system restart. Fig. 25: Adding IP address settings CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 80 Standard gateway: 0.0.0.0 Parameterization of the desired IP address, network mask and standard gateway is only possible in parameterization mode. The possibly necessary switching into parameterization mode via the operating unit is described below. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 81 Now select the address which you would like to configure and/or check: – IP address – MAC address – Gateway address – Network mask (subnet mask) The individual octets are accepted by pressing the "Enter" key. You can always get back with the "ESC" key. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 82 This mode is very well suited for initial commissioning in order to put the system under pressure independently of the set field bus communication. Moreover, the system can be bled in this mode. Fig. 27: Easy startup mode Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 83 All field buses available to the IndraDrive are supported: Fig. 28: Connection to the control system Bosch Rexroth recommends activating the control communication only after the remaining configuration of the IndraDrive and the technology function. Repeated phase switching of the drive state machine, which is necessary for commissioning, leads to delays in machine commissioning under an active field bus.
  • Page 84 1. Activating the field bus (P-0-4089.0.1 = 4) Fig. 29: Field bus start dialog Restart (C6400) required! 2. The slave address (P-0-4025) can be set optionally; the communication is IP-based and is configured via the device name on the superior controller. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 85 Fig. 30: Activating the freely configurable mode 4. Configuring cyclic actual values (AT) and command values (MDT) ▶ Configure cyclic actual values (AT) and command values (MDT) as required from Table 44 on page 91. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 86 1. Activating the field bus (P-0-4089.0.1 = 3) Fig. 31: Activating the EtherNet/IP™ Restart (C6400) required! 2. The slave address (P-0-4025) can be set optionally; the communication is IP-based and is configured on the superior controller. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 87 Fig. 32: Activating the freely configurable mode 4. Configuring cyclic actual values (AT) and command values (MDT) ▶ Configure cyclic actual values (AT) and command values (MDT) as required from Table 44 on page 91. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 88 2. Profile type "Servodrive Profile" (P-0-4084 = 0x0002) 3. Configuring cyclic actual values (AT) and command values (MDT) ▶ Configure cyclic actual values (AT) and command values (MDT) as required from Table 44 on page 91. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 89 2. Profile type "Servodrive Profile" (P-0-4084 = 0x0402) 3. Configuring cyclic actual values (AT) and command values (MDT) ▶ Configure cyclic actual values (AT) and command values (MDT) as required from Table 44 on page 91. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 90 On the control side, the CytroBox is not to be set up as an IndraDrive but as a Sercos I/O device. 3. Configuring cyclic actual values (AT) and command values (MDT) ▶ Configure cyclic actual values (AT) and command values (MDT) as required from Table 44 on page 91. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 91 Particle content L SC/EC/PN/EIP Optional P-0-1427 Particle content XL SC/EC/PN/EIP Optional ProfiNet EtherNet Sercos EtherNetIP The ProfiNet communication of the CytroBox allows a maximum of 48 byte / 24 words. Further communication via parameter channel or multiplexer. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 92 FALSE = commanding p from cyclic customer interface for IMC TRUE = commanding p from fixed command value memory Selection Commanding speed FALSE = commanding n from cyclic customer interface for IMC TRUE = commanding n from fixed command value memory Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 93 Any changes that are necessary nonetheless can be made via parameter P-0-1380. Moreover, the threshold values can be adjusted, if necessary. Only carry out changes if they are absolutely necessary and you have agreed them with Bosch Rexroth. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 94 Fig. 36: Start dialog of the IMC software / parameter file The optimized parameters are imported during production and can be maintained for most applications. These instructions can be used for any necessary optimization/adaptation of the pressure values. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 95 Configuration of the IMC controller 3. Diagnosis: Status display and issue of warnings and errors 4. Configuration: Information on the settings of the overall system (hardware and software) These four functions can be displayed with the IndraWorks. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 96: Re-Commissioning After Longer Standstill

    – the hydraulic fluid level – hydraulic components and line systems for tightness ▶ Switch on components with increased caution. ▶ Bleed the hydraulic system. ▶ Observe the information in the operating instructions of the machine/system manufacturer. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 97: Operation

    Information on operating the hydraulic power unit can only be provided in connection with the machine/system. For this information, please refer to the operating instructions of the machine/system manufacturer. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 98: Maintenance And Repair

    Do not use compressed air for the cleaning at functional interfaces. ▶ Remove external coarse dirt and keep sensitive and important parts like electrical connections clean. ▶ For the cleaning, use a damp, non-linting cloth or residue-free industrial wipes. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 99: Inspection

    Maintenance and repair 99/128 10.2 Inspection Bosch Rexroth recommends documenting the inspection results so that • considering functionality and economy, the inspection and maintenance intervals can be adjusted to the actual operating conditions. • by comparing the documented values, you can identify faults at an early point in time.

  • Page 100: Maintenance Schedule

    Check the power unit housings, cables and plug-in connections and connector contacts for damage. Inadmissible damage includes breaks, cracks, abrasion, deformation or discoloration. The hydraulic power unit may only be operated if the electric components are not damaged. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 101: Filling Level Monitoring

    (e.g. maximum pressure limit, pump control, pressure reducing valve) • Error at the pump (wear, increased leakage) • Changed environmental conditions (e.g. increased ambient temperature) • Changed load conditions at drives In case of inadmissible temperature increases, the causes must be determined and corrected. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 102: Monitoring The Filter Element Contamination (Pressure Filter)

    Fig. 9 on page 52, and start the drive in service mode (via the wizard or IndraWorks DS). Check the oil level and refill appropriate hydraulic fluid, if necessary. Dispose of the filter element in accordance with national or company-specific regulations. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 103: Visual Inspection Of The Air Filter

    The pressure values need to be checked in case of any changes in drive behavior (e.g. increased cycle time, end product quality, etc.). Otherwise, semi-annual inspections are recommended. Bosch Rexroth recommends documentation of pressure values in the maintenance documentation. 10.5.7 Hydraulic fluid care The hydraulic fluid should be analyzed at least annually.

  • Page 104: Visual Inspection For Leakage, Cracking, Force Effects And Corrosion

    In case of indications of corrosion, the component must be checked for damage and assessed for further reliable use. As required, this component is to be replaced or thoroughly repaired. In any case, corrosion protection must be ensured. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 105: Spare And Wear Parts

    Maintenance and repair 105/128 10.6 Spare and wear parts ▶ For a list of spare and wear parts for the hydraulic power unit, refer to Fig. 38 and Table 50: Fig. 38: Spare and wear parts CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 106 TU1-X-PUR-016-2500-BK-0025-WH 4101 R412007956 ELBOW UNION QR2-S-RVT-G012-DA16 4102 R412004794 PUR TUBING TU1-X-PUR-016-2500-BK-0025-WH 4111 R412007956 ELBOW UNION QR2-S-RVT-G012-DA16 4112 R901521022 CORRUGATED HOSE CB DN20 550MM/G1-G1 4140 R911286923 POWER-LINE FILT. NFD03.1-480-130 6070 R901503635 FLOAT SWITCH ABZMS-41-1X/0500/LTD/DC-K24 6120 Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 107 MOUNTING PLATE CYTROBOX-EMPTY 8010 ▶ Please send any spare part orders to the nearest Bosch Rexroth service center or directly contact the headquarters. For the addresses, please refer to www.boschrexroth.com. ▶ Order spare parts in writing. In urgent cases you can also order by phone, but you Spare parts order are kindly requested to confirm your order in writing e.g. by fax.

  • Page 108: Decommissioning

    CEJN567-G1/2-020-105676200, see Fig. 8, pos. 15 on page 51. – In this connection, ensure complete draining of the lines and actuators. If necessary, carry out bleeding measures. Overall machinery/system Decommission the overall machinery/system as described in the overall machinery/system operating instructions. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 109: Disassembly And Replacement

    For this reason, close all outlets of lines with suitable blanking plugs. After disassembly, observe the information on safe transport of the product in chapter 6 "Transport and storage". CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 110: Disposal

    Dispose of the hydraulic power unit and the packaging material in accordance with the applicable national regulations in your country. ▶ Dispose of the hydraulic fluid in accordance with the currently applicable national regulations in your country. Also observe the applicable safety data sheets. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 111: Extension And Modification

    Declarations become Bosch Rexroth, this means you are changing the condition as supplied. invalid Any statements made by Bosch Rexroth regarding this product will then become invalid. For hydraulic power units, this has the following consequence: Hydraulic power units are partly completed machines in the sense of the EC Machinery Directive 2006/42/EC.

  • Page 112: Troubleshooting

    • Was the hydraulic power unit or the machine/system used as intended? • How did the fault become apparent? • Try to get a clear idea of the cause of error. ▶ Ask the direct (machine) operator, if necessary. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 113: Overview Of The Impact Of Defects

    – Speed limitation via field bus presetting – Fixed command value memory speed limitation ▶ Observe the maximum admissible speed of the application. – If necessary, contact the Bosch Rexroth customer service. Overload of the drive Drive insufficiently dimensioned ▶ Indicator in display "drive overload torque"...
  • Page 114 Compare the results with the selected oil cooling power of the hydraulic power unit. ▶ Reduce the cooling water temperature, increase the cooling water flow or contact the Bosch Rexroth customer service to install an external oil cooling, if necessary. ▶ Check if the cooling circuit is starting up.
  • Page 115 Insufficient hydraulic fluid temperature or ▶ Increase the temperature of the hydraulic power unit high viscosity class too high before starting the machine function. ▶ If necessary, use hydraulic fluid with a lower viscosity class. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 116: Technical Data

    Effective filtration prevents faults and simultaneously increases the life cycle of the components. For selecting the filters, see www.boschrexroth.com/filter. Directly mounted at the block. For further information and data on the use of other hydraulic fluids, please contact us. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 117 The power unit requires a cooling water connection; the oil temperature can be set by means of parameters. The control cabinet is air-cooled and the electric motor is water-cooled. The hydraulic fluid is cooled by a circulation circuit with a plate heat exchanger. CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...

  • Page 118: Appendix

    118/128 Appendix 17 Appendix 17.1 List of addresses For the addresses of our sales and service network, please refer to www.boschrexroth.com. Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 119: Declaration Of Incorporation

    Appendix 119/128 17.2 Declaration of incorporation CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 120 120/128 Appendix Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 121: Prohibited Substances - Reach, Rohs, Weee

    We regularly check our products for the use of hazardous substances (SVHC), buy our components exclusively from qualified suppliers and ensure with the compliance of the Bosch standard N2580 that our AB products do not pose any danger to people and the environment.

  • Page 122: Accessories

    (included in the scope of delivery) The accessories listed in table Table 52 can be ordered separately under the specified material numbers. The IndraWorks DS software can be downloaded from the link https://www.boschrexroth.com/indraworks - Download Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...

  • Page 123: Alphabetical Index

    Configuration of the operating points Flushing the hydraulic system Connection establishment Functional description to the CytroBox (IndraDrive) Connection to the control system ▶ H Control communication Hydraulic fluid care Control questions Hydraulic supply connection CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 124 – Oil level Selection of the operating – Oil temperature point in fixed command value mode – Particle concentration Sensor evaluation – Relative humidity – Dissolved air inclusion Monitoring the oil temperature – Fluid detection Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 125 – Using forklifts and similar floor conveyors – Using lifting gear Troubleshooting ▶ U Unpacking ▶ V Visual inspection for leakage, cracking, force effects and corrosion Visual inspection of the air filter Voltage supply feed-in assignment ▶ W Warning devices CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 126 126/128 Appendix Notes Bosch Rexroth AG, CytroBox, RE 51057-B/11.19...
  • Page 127 Appendix 127/128 CytroBox, RE 51057-B/11.19, Bosch Rexroth AG...
  • Page 128 Bosch Rexroth AG Industrial Hydraulics Zum Eisengießer 1 97816 Lohr am Main Germany Phone +49 (0) 9352 / 40 30 20 my.support@boschrexroth.de www.boschrexroth.com For your local contact partner, please refer to: www.boschrexroth.com Subject to change without notice Printed in Germany RE 51057-B/11.19...

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