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Bosch rexroth HS5E Instruction Manual

For axial piston variable pump a4vso, a4vbo, a4vsg and a4csg
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Table of Contents
Instruction manual
Control system HS5E(V)(L)
for Axial piston variable pump
A4VSO, A4VBO, A4VSG and A4CSG
RE 92076-01-B/2021-04-22, replaces: 10.2017, DE

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  Summary of Contents for Bosch rexroth HS5E

  • Page 1 Instruction manual Control system HS5E(V)(L) for Axial piston variable pump A4VSO, A4VBO, A4VSG and A4CSG RE 92076-01-B/2021-04-22, replaces: 10.2017, DE...
  • Page 2 © Bosch Rexroth AG 2021. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The data specified within only serves to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived...
  • Page 3: Table Of Contents

    5.6.2 Pulsation damper ..................32 Master/slave operation ................32 5.7.1 Circuitry of HS5E(V)(L) ................33 Description of the IndraWorks commissioning tool ........35 5.8.1 System requirements .................35 5.8.2 Firmware update ..................36 Switch-on sequence of electronics/hydraulics ...........36 5.10 Product identification .................37 Transport and storage ................38 RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 4 8.1.6 Switching on the drive motor of the pump ..........75 8.1.7 Setting controller parameters ..............76 8.1.8 Calibrating the HS5E(V)(L) control system ..........80 8.1.9 Saving parameters ..................82 Running-in phase ..................82 Recommissioning after standstill ...............83 Operation ....................84 Maintenance and repair ................85 10.1 Cleaning and care ..................85 Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 5 Extension and conversion ............... 91 Troubleshooting ..................92 14.1 How to proceed for troubleshooting ............92 14.2 Error/diagnosis memory ................93 14.2.1 Fault diagnosis ...................93 14.3 Malfunction table ..................94 14.3.1 Swivel angle measurement check .............100 Technical data ..................101 Alphabetical index ................102 RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 6: About This Documentation

    Installation drawing Contains the outer dimensions, all ports and the hydraulic drawing from your contact at Bosch Rexroth. circuit diagram for your axial piston variable pump A4... with HS5E(V)(L) control system. Axial piston variable pump A4... with HS5E(V)(L) control system...
  • Page 7: Representation Of Information

    Always follow the measures for danger prevention associated with the use of this product. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 8: Symbols

    Table 3: Meaning of symbols Symbol Meaning If this information is disregarded, the product cannot be used and/or operated to its full extent. ▶ Single, independent action Numbered instruction: The numbers indicate that the actions must be completed in order. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 9: Designations

    International Organization for Standardization Japan Industrial Standard Rexroth document in the English language VDI 2230 Directive for the systematic calculation of high duty bolted joints and joints with one cylindrical bolt from the VDI (Verein Deutscher Ingenieure - Association of German Engineers) RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 10: Safety Instructions

    Operation is only allowed if you comply with national EMC regulations for the present application. If you need information about EMC-compliant installation, refer to Bosch Rexroth’s EMC test documentation (see data sheet 92076). Ensuring compliance with the limit values required by national regulations is the responsibility of the manufacturer of the system or machine.
  • Page 11: Improper Use

    2.3 Improper use Any use other than that described as intended use is considered improper. Bosch Rexroth AG is not liable for damages resulting from improper use. The user is solely responsible for any risks arising from improper use. The following foreseeable forms of faulty usage are also considered improper (this list is not exhaustive): •...
  • Page 12: General Safety Instructions

    • In particular, fully understanding the relationships with regard to safety devices • and understanding how electrical components function and are put together. Bosch Rexroth offers you measures supporting training in specific areas. You can find an overview of the training contents on the Internet at: www.boschrexroth.com/training.
  • Page 13: Product-Specific Safety Instructions

    ▶ Changes to the factory settings may only be made by Bosch Rexroth specialists. ▶ In addition, a pressure relief valve is required in the hydraulic system as back- up.
  • Page 14 Danger to life or risk of injury due to electric shock or property damage! ▶ Always diskonnect the voltage supply to the relevant machine/system part before assembling the product and/or connecting or diskonnecting the connector. Protect the machine/system against being re-energized. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 15 The noise emission of axial piston units depends on rotational speed, working pressure and installation conditions, among other factors. The sound pressure level may rise above 70 dB (A) in certain application conditions. ▶ Always wear hearing protection near a running axial piston unit. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 16 Limiting the minimum displacement can cause torque to be generated in the application. Check whether additional measures are necessary on your machine for the application in order to guarantee that the torque is switched off. If necessary, make sure these are appropriately implemented. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 17: Personal Protective Equipment

    2.7 Personal protective equipment Personal protective equipment is the responsibility of the user of the axial piston unit with HS5E(V)(L) control system. Observe the safety regulations in your country. All pieces of personal protective equipment should be intact. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 18: General Instructions On Property Damage And Product Damage

    ▶ With above-reservoir installation, an axial piston unit must be moved to full swivel angle after no more than three seconds during commissioning and recommissioning. Make sure that the axial piston unit really does suck in hydraulic fluid and build up pressure. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 19 ▶ Dispose of the axial piston unit, hydraulic fluid and packaging in accordance with the regulations in your country. ▶ Dispose of the hydraulic fluid in accordance with the applicable safety data sheet for the hydraulic fluid. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 20 The warranty exclusively applies to the delivered configuration. The warranty will be voided if the product is incorrectly installed, commissioned or operated, or if it is used or handled improperly. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 21: Scope Of Delivery

    • For version with optional through drive (U99) plugged with pressure-tight cover (4) • HS5E pilot control valve (5) • Swivel angle sensor (6) • Pressure transducer (1x with open circuit, 2 pieces with closed circuit) including cable (7) (only with HS5E(V)(L)P) RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 22: About This Product

    Fig. 2: Cutaway diagram of A4VSO..HS5E and HS5EV (HS5E pilot control valve shown rotated by 90°) 1 HS5E pilot control valve 5 Stroking piston for 6 Stroking piston for 2 Stroking piston HS5E HS5EV 3 Swashplate 4 Swivel angle sensor Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 23: Functional Description Hs5E(L)

    An electrically actuated proportional valve with OBE (1) controls the swivel angle and pressure of the A4V... variable pump and limits its torque. By means of the pump's stroking piston (2), this valve determines the position of the swashplate (3). RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 24: Parallel And Cascade Control Of The Hs5E(V)(L) Control System

    In the possible operating modes, up to two controllers are continuously active: Basic operating modes • Swivel angle controller • Pressure controller These controllers alternate automatically and on a stepless basis by means of the switching logic. The controller takes over whose actual value has best approximated the command value. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 25: Parallel Control Structure

    It is possible to modify the output parameter of the pump switching logic using different characteristic curves and functions in the pump manipulated variable RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 26: Cascading Control Structure

    In actual pressure value acquisition, the system compares the different actual pressure values and generates from them the resulting sign for the switching logic. The output of the swivel angle controller is passed on to the manipulated variable adjustment of the swivel angle controller. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 27: Controller Parameters (Parallel)

    HS5E The HS5EV control system starts without load pressure with maximum swivel angle Starting up at zero pressure (+100% V ). This may result in pressure peaks in the system until the system is HS5EV g max adjusted. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 28 125 to 1000 and can be bled via the ports R2 to R7. Check whether or not your machine requires additional safety measures for your application to avoid unintentional movement. If necessary, make sure these are appropriately implemented. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 29: Working Pressure Limits

    – Standard version A4VSO and A4VBO to swivel angle α = -100% (V g min This can lead to cavitation and damage to the pump. You can find the maximum and minimum pressures in data sheet 92076. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 30 A4CSG to swivel angle α =-100%. Limiting the minimum displacement can cause torque to be generated in the application. Check whether additional measures are necessary on your machine for the application in order to guarantee that the torque is switched off. If necessary, make sure these are appropriately implemented. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 31: Ambient Conditions

    Frequently, this leads to other components being stimulated too, which creates noises. This means that when check valves are used, for example, it may be necessary to adapt the springs that are used to the conditions in the system if stimulation with noise generation happens. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 32: Noise Development In The Unit

    The master now regulates both the pressure and the swivel angle according to the external command value specifications and passes on its internal swivel angle command value to the slave pumps as the swivel angle command value. This guarantees even and synchronous swiveling. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 33: Circuitry Of Hs5E(V)(L)

    5 α 5 α α (II) α 0 V actual 10 p high 10 p high actual 11 p 11 p actual (II) Slave Master Fig. 7: Example of HS5E(V)(L) for (analog) master/slave operation and independent individual operation; alternatives possible RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 34 All of the analog inputs that are not used, e.g. the actual pressure value input in the case of swivel angle control, must be interconnected with 0 Volts. electrical signal inputs Notwithstanding, unused differential amplifier inputs can also be short-circuited. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 35: Description Of The Indraworks Commissioning Tool

    There is one option for configuring and parameterizing the HS5E(V)(L) control system: ▶ Using the Bosch Rexroth’s IndraWorks software. For the HS5E(V)(L) control system, the current IndraWorks version must be used. The IndraWorks Ds software is available for free on the Rexroth website at the following link: www.boschrexroth.de/HS5E...
  • Page 36: Firmware Update

    Open the isolator valve (if present) Switch off: • Command value specification: α = 50% and p = 20 bar • Close the isolator valve (if present) • Suppress the warnings • Switch off the electric motor • Switch off the electronics voltage supply Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 37: Product Identification

    4 Direction of rotation (viewed on drive 11 Serial number shaft) – here: clockwise 12 Material number of the axial piston 5 Bar code unit 6 Power setting (optional) 13 Type code 7 Rotational speed 14 Customer material number RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 38: Transport And Storage

    ▶ Make sure that the eye bolt can bear the total weight of the axial piston unit plus 20%. You can hoist the axial piston unit with the eye bolt screwed into the drive shaft, as shown in Fig. 9. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 39 ▶ Place the lifting strap around the axial piston unit so that it does not pass over assembled parts (e.g. valves, electrical assembled parts, and sensors (red arrows see Fig. 10)) and that the axial piston unit is not suspended from assembled parts. Fig. 10: Transporting the axial piston unit RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 40: Storing The Axial Piston Unit

    Once the max. storage time has elapsed, we recommend that you have the axial piston unit checked by your Bosch Rexroth service partner. For questions regarding repair and spare parts, contact your proper Bosch Rexroth service partner or the service department of the manufacturer's plant of the axial piston unit, see chapter 10.5 "Spare parts"...
  • Page 41 In such a case, consult your local contact person; you can find their contact information at www.boschrexroth.com/addresses. Bosch Rexroth recommends the following procedure: 1. Clean the axial piston unit, see chapter 10.1 "Cleaning and care" on page 85. 2. Drain the axial piston unit.
  • Page 42: Installation

    • Installation drawing for the axial piston unit (can be obtained from your contact person at Bosch Rexroth, if required) • Hydraulic circuit diagram for the axial piston unit (in the data sheet and on the installation drawing) •...
  • Page 43 ▶ Use fiber-free cloths for cleaning. ▶ Use suitable, mild cleaning agents to remove lubricants and other heavy contamination. Do not allow cleaning agents to enter into the hydraulic system. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 44: Installation Position

    = 800 mm. The S max permissible suction height h is derived from the total pressure loss. Recommendation for installation position 6 (drive shaft upward): A check valve in the drain line (cracking pressure 0.5 bar) can prevent the housing area from draining. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 45: Installing The Axial Piston Unit

    1. Compare the material number and designation (type code) with the parameters in the order confirmation. If the material number for the axial piston unit does not match the one in the order confirmation, contact your local contact person for clarification. You can find their contact information at www.boschrexroth.com/addresses. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 46: Dimensions

    Belts can lose much of their pre-charge pressure after just a short operating time. An automatic clamping device can lessen the speed variations and vibrations, and thus avoid subsequential damage. – When using drives with toothed belts or V-belts, always use an automatic clamping device. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 47: Installation With A Coupling

    7. Align the drive shaft of the axial piston unit and the output shaft of the drive motor so there is no angular deviation. 8. Make sure no excessive axial and radial forces are acting on the drive shaft. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 48: Installation On A Gearbox

    Use a suitable tool for this to prevent damage to the sealing and functional surface. If the sealing or functional surface is damaged, contact your Bosch Rexroth service partner or the service department of the manufacturer's plant for the axial piston unit.
  • Page 49 Use a suitable tool for this to prevent damage to the sealing and functional surfaces. If sealing or functional surfaces are damaged, contact your Bosch Rexroth service partner or the service department of the manufacturer's plant of the axial piston unit.
  • Page 50: Hydraulically Connecting The Axial Piston Unit

    – The hose must be pressure-resistant, also to external air pressure. • Pressure line – For the pressure lines, use only pipes, hoses and connecting elements rated for the operating pressure range specified in data sheet 92050 (see table 13). Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 51 ▶ Make sure the right fittings, mounting bolts and threaded plugs are installed. ▶ For all female threads, use a stud end from the same system of units and of the correct size. Port overview A4VSO R(L) Fig. 16: Example A4VSO 125 to 355/30 with HS5E pilot control valve, clockwise rotation RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 52 A4VSG R(L) Fig. 18: Example A4VSG 125 to 355/30 with HS5E pilot control valve, clockwise rotation Port overview A4CSG R(L) Fig. 19: Example A4CSG 500/30 with HS5EP control system, clockwise rotation Ports for A4CSG with HS5EL on request Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 53 Version 13: for A4VSO NG 40 to 355 Version 25: for A4VSO NG 40 to 1000 Must be connected for version for HFC hydraulic fluids Only available for open circuit O = Must be connected (plugged on delivery) X = Plugged (in normal operation) RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 54 Inductive position transducer for valve position X8A actual swivel angle input Reserved, X2N Configurable sensor interface X2M2 (pressure sensor input) Configurable sensor interface X2M1 (pressure sensor input) Multi-EtherNet interface X7E1 Multi-EtherNet interface X7E2 Plug-in connector XH4 VT-SWA-LIN..Swivel angle sensor Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 55 The tightening torques for the threaded plugs are valid for the condition "dry" and "lightly oiled". The tightening torques for the threaded plugs are valid for the condition "dry" – in the condition "lightly oiled", the tightening torques for M10 × 1 are reduced to 10 Nm and for M12 × 1.5 to 17 Nm. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 56: Electrically Connecting The Axial Piston Unit

    92076, e.g.: • Permissible voltage range • Permissible current • Correct pin assignment • An Ethernet M12 to RJ45 connection cable (ports X7E1 & X7E2), additional information in type designation RKB0044/xxx.x (xxx.x: length in meters) Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 57: Performing Flushing Cycle

    57/104 7.5 Performing flushing cycle In order to remove foreign particles from the system, Bosch Rexroth recommends a flushing cycle for the hydraulic system before the first commissioning. To avoid internal contamination, do not include the axial piston unit in the flushing cycle.
  • Page 58: Connection To The Swivel Angle Sensor

    Sensor signal input voltage (0 … 10V) Negative differential amplifier input to pin 4 (optional) Maximum load capacity 50 mA, voltage output same as connected voltage supply at input XH4. Only one signal input per interface can be configured Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 59: X7E1 And X7E2: Plug-In Connector Assignment For Ethernet Interface (Coding D), M12, 4-Pin, Socket

    - Link: Cable is plugged in, connection has been established (lit up permanently) - Activity: Data has been sent/received (flashing) Module status LEDs 3 and 4 refer to the electronics module For a detailed description of the diagnosis LEDs, refer to the functional description of the Rexroth HydraulicDrive. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 60: Voltage Supply Of The Hs5E Pilot Control Valve

    The HS5E pilot control valve does not have an enable input to block the function of the valve. In the event of a fault, the drive enable should be canceled via fieldbus. All other safety-relevant intervention must be carried out by the higher-level control (e.g. drive motor OFF, close isolator valves, etc.) Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 61: Selection, Installation Location, And Installation Direction Of The Pressure Transducer

    The pressure transducer is connected to ports X2M1 and X2M2. Alternatively, it can connection also be connected to the HS5E pilot control valve via the central connector. In case of connection of the pressure transducer via the central connector, the supply voltage must comply with the specification. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 62 (and any associated control oscillations) right from the start. the pressure transducer If the installation position of the pump leads to a pressure transducer that is installed directly into the pump being positioned vertically, we recommend choosing a different installation position for the pressure transducer. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 63: Commissioning

    Commissioning an incorrectly installed product! Risk of injury and property damage! ▶ Make sure that all the electrical connections and hydraulic ports are connected or plugged correctly. ▶ Commission only a fully installed, fully functioning product with original accessories from Bosch Rexroth. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 64 This message is output as an analog signal and it can be further- processed. ▶ Using the machine control unit, you must ensure that the system is transferred to a safe state. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 65: Initial Commissioning

    Professional filling and air bleeding is required to prevent damage to the axial piston unit and to maintain proper function. Bosch Rexroth evaluates hydraulic fluids on the basis of the Fluid Rating according to data sheet 90235. For hydraulic fluids which have been positively evaluated in the Fluid Rating, please refer to data sheet 90245 "Bosch Rexroth...
  • Page 66: Testing The Hydraulic Fluid Supply

    Refer to data sheet 92050 for the permissible value. 6. At maximum pressure, check the leakage pressure at port K , or K . For the permissible value, please refer to the data sheets from Table 1 "Required and supplementary documentation" on page 6. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 67: Performing A Functional Test

    The default address of the HS5E pilot control valve is 192.168.0.1. If the IP address is incorrect, the row is highlighted in red. After you have configured the network port, you can open IndraWorks and start a network search: RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 68: Making The Basic Setting On The Control Electronics

    • Pressure acquisition settings (only with HS5E(V)(L), not HS5E(V)(L)P if using the pressure transducer included in the scope of delivery) • Setting of torque limitation • Controller optimization (see chapter 8.1.7 "Setting controller parameters" on page 76 or also refer to the additional information in data sheet 30237-Z). Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 69 (see data sheet 30237-Z and firmware and software description 30338-FK) To set the enable during commissioning, you use Easy Startup mode. You use IndraWorks to configure this mode and to start it. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 70 A4VSG and The HS5E pilot control valve gives you the option of connecting two pressure A4CSG transducers. For this, you must configure two assignments for the corresponding analog inputs with destination actual pressure value A (S-0-0803) and actual Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 71 To protect the drive motor from overloading, it is possible to limit the maximum torque of the pump. Parameter "P-0-2952, Torque limitation of pump, relative" is a relative variable in percent and is relative to the maximum torque of the pump at normal pressure (P-0-2957.0.1). RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 72 × Δp Power [kW] 60000 600 × η Displacement per revolution [cm Δp Differential pressure [bar] Rotational speed [rpm] η Volumetric efficiency η Hydraulic-mechanical efficiency η = η × η Total efficiency (η Fig. 25: Parameters for torque limitation Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 73 If the type of swivel angle sensor changes or the HS5E pilot control valve is replaced, you may need to modify the selection values in the "Actual swivel angle value acquisition" window appropriately. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 74 Via the structure tree "System pump controller" → "Pump/drive motor" you can open the following window. In this window, you must check the values for the displacement of the pump, the direction of rotation, the hydraulic version, the system/control and the drive speed and, if required, adjust them. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 75: Switching On The Drive Motor Of The Pump

    Later, when the motor is running, this warning should no longer be issued. To suppress the warning while the motor is at a standstill, you can enter a swivel angle command value of < 5% RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 76: Setting Controller Parameters

    The lower this value is set, the slower is the controller’s response. However, if you select a value that is too high, the system can become unstable. When customizing the controller parameters to plant-specific behavior, you generally only need to modify the P-gain in the pressure controller. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 77 D-component does not respond, since the change rate is zero. The higher the D-component, the slower is the system’s response. With the cascade structure, the D component is only used to increase damping in the controller on an as required basis. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 78 Check the value of the dead volume (P-0-2813) and correct it (damped oscillation) if necessary. Overshoots Increase feedback of integrator (P-0-2812) to reduce initial (damped oscillation) overshoots Actual pressure value Reduce P-gain (P-0-2809); if necessary, increase D still overshooting component Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 79 Rapid but unstable Check the value of the dead volume (P-0-2813) and correct it response if necessary. Reduce P-gain (P-0-2809); if necessary, reduce D component Increase the integration time (P-0-2806.0.4) Reduce parameter for feedback derivation actual pressure value (P-0-2812) RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 80: Calibrating The Hs5E(V)(L) Control System

    Calibration of the swivel angle sensor’s offset Calibration of the swivel angle sensor’s gain Calibration of leakage compensation You can find further information about configuring and controlling the calibration functions in the functional description of the HydraulicDrive firmware (data sheet 30330-RN). Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 81 Attention: the calibration function of the swivel angle zero point does not ensure that the pressure in A and B is reached in the closed circuit at 0% swivel angle specification. If this is desired, the swivel angle zero point has to be readjusted manually. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 82: Saving Parameters

    10 operating hours is concluded. To ensure that contamination in the hydraulic system does not damage the axial piston unit, Bosch Rexroth recommends the following procedure after the running- in phase: Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 83: Recommissioning After Standstill

    The following criteria may make recommissioning necessary: • Air in the hydraulic system • Water in the hydraulic system • Old hydraulic fluid • Other contamination ▶ For recommissioning, proceed as described in chapter 8.1 "Initial commissioning" on page 65. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 84: Operation

    For this reason, this chapter of the manual does not contain any information on adjustment options. Use the product only within the performance range specified in the technical data. The machine/system manufacturer is responsible for proper project planning of the hydraulic system and its control. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 85: Maintenance And Repair

    ▶ Use only water and, if necessary, a mild cleaning agent to clean the axial piston unit. Never use solvents or aggressive cleaning agents. ▶ Remove major external contamination and keep clean sensitive and important components, such as solenoids, valves, indicators and sensors. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 86: Inspection

    A4... with HS5E(V)(L) control system Series 1x and 30 | Maintenance and repair 10.2 Inspection In order to keep the axial piston unit running reliably for a long time, Bosch Rexroth recommends testing the hydraulic system and axial piston unit on a regular...
  • Page 87: Repair

    Maintenance and repair | A4... with HS5E(V)(L) control system Series 1x and 30 87/104 10.4 Repair Bosch Rexroth offers a comprehensive range of services for the repair of Rexroth axial piston units. Repairs on the axial piston unit and its assembled parts should only be performed by service centers certified by Bosch Rexroth.
  • Page 88 When replacing it, make sure that no contaminants enter fluid-carrying parts of the valve and the pump. Before replacing the new control valve, Bosch Rexroth recommends saving the parameters of the valve to be replaced and to transfer the data to the replacement valve.
  • Page 89 If used properly, the IP 67 degree of protection is guaranteed without retightening. One-off retightening is possible. However, it is advisable not to retighten the plug-in connection on a regular basis, since this affects the electrical properties of the seal and its correct function. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 90: Removal And Replacement

    6. Remove the axial piston unit. Use a suitable lifting device. 7. Completely drain the axial piston unit. 8. Plug all openings. 11.4 Preparing the components for storage or further use ▶ Proceed as described in chapter 6.2 "Storing the axial piston unit" on page 40. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 91: Disposal

    Changes to settings on the customer side should only be made using the product- specific setting instructions. The warranty from Bosch Rexroth only applies to the configuration as delivered. Any modification, extension or software customization voids the warranty. Setting screws are protected against unauthorized adjustment by tamper-proof caps.
  • Page 92: Troubleshooting

    ▶ Try to get a clear idea of the cause of the fault. Directly ask the (machine) operator. ▶ Document the work carried out. ▶ If the fault cannot be corrected, please refer to one of the contract addresses www.boschrexroth.com/addresses. Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 93: Error/Diagnosis Memory

    0. Here, the following applies: Table 26: Messages Meaning of the message Output signal at pin 3 Electronics OK 24 V Fault message present or no controller 0 V enable set RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 94: Malfunction Table

    Mechanical damage to the axial piston unit Replace axial piston unit (e.g. bearing damage) Contact Bosch Rexroth Service Increased, unusual vibration Bearings worn Contact Bosch Rexroth Service Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 95 Contact Bosch Rexroth Service of the axial piston unit Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service...
  • Page 96 Contact Bosch Rexroth Service of the axial piston unit Control of the control device defective Check control (contact machine/system manufacturer or Bosch Rexroth Service) Wear or mechanical damage to the axial piston Replace axial piston unit unit Contact Bosch Rexroth Service Output unit defective (e.g. hydraulic motor or...
  • Page 97 Contact Bosch Rexroth Service Contact machine/system manufacturer Axial piston unit worn Replace axial piston unit; contact Bosch Rexroth Service Table 28: Malfunction table of HS5E control systems Malfunction Possible cause Remedy Message "analog input, wire...
  • Page 98 Faulty mechanical drive (e.g. defective coupling) Machine or system manufacturer (< 4 bar) Hydraulic fluid not in optimal viscosity range Use suitable hydraulic fluid (machine or system manufacturer) Output unit defective (e.g. hydraulic motor or Machine or system manufacturer cylinder) Wear/mechanical damage Replace the control system, contact Rexroth Service Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 99 Rotational speed speed too low (slip, incorrect Contact machine or system manufacturer frequency, wrong motor) Damage to the pump (excessive pump leakage) Rotary group damaged, Contact Rexroth Service Wear/mechanical damage to the control system Replace the control system, contact Rexroth Service RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 100: Swivel Angle Measurement Check

    The settings for swivel angle measurement are made at the factory. After you have replaced the swivel angle sensor, you must carry out calibration; see chapter 8.1.8 "Calibrating the HS5E(V)(L) control system" on page 80. Bosch Rexroth recommend repeating calibration or checking it at certain intervals.
  • Page 101: Technical Data

    The permissible technical data for your axial piston unit can be found on the data sheet 92076. The data sheet can be found on the Internet and/or in the online product catalog www.boschrexroth.de/HS5E Order-related technical data for your axial piston unit can be found in the order confirmation. RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 102: Alphabetical Index

    ......34 Maximum working pressure ..29 Eye bolt ........38 Name plate ........37 Fault diagnosis ......93 Noise development ....... 31 Filling ........... 65 Notes Flushing cycle ....... 57 General ........46 Functional test ......67 Bosch Rexroth AG, RE 92076-01-B/2021-04-22...
  • Page 103 Running-in phase ......82 Safety instructions ....... 10 General ........12 Product-specific ......13 Signal word ........8 Scope of delivery ......21 Seal kits for the pump ....88 Spare parts ........87 Stand-by operation ....... 28 RE 92076-01-B/2021-04-22, Bosch Rexroth AG...
  • Page 104 Bosch Rexroth AG An den Kelterwiesen 14 72160 Horb a.N. Germany Tel. +49 7451 92-0 sales.industry.horb@boschrexroth.de www.boschrexroth.com Your local contact person can be found at: www.boschrexroth.com/addresses Subject to change Printed in Germany RE 92076-01-B/2021-04-22...

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