Bosch SYEPS 1X Series Operating Instructions Manual
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Bosch SYEPS 1X Series Operating Instructions Manual

Highly dynamic electrohydraulic punching system for nc punching machines
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SYEPS series 1X
Highly dynamic electrohydraulic punching system for NC punching
machines
Operating instructions
RE 30201-B/07.2014
Replaces: 11.2012
English

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Summary of Contents for Bosch SYEPS 1X Series

  • Page 1 SYEPS series 1X Highly dynamic electrohydraulic punching system for NC punching machines Operating instructions Replaces: 11.2012 RE 30201-B/07.2014 English...
  • Page 2 © This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth. It may not be reproduced or given to third parties without its consent. An example configuration is shown on the title page.

  • Page 3: Table Of Contents

    Transporting and storing the HNC100 and electronics Installation Unpacking Installation conditions 7.2.1 For the HNC100 7.2.2 For the SYEHL punching axis Installation orientation and piping of SYEHL punching axes 7.3.1 General Recommended accessories Installing the SYEPS punching system RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 4 9.3.1 Machine data 9.3.2 R parameters 9.3.3 Process variables 9.3.4 Measurement 9.3.5 Data transmission HNC100 error messages - error handling Maintenance and repair 10.1 Cleaning and care 10.2 Maintenance and inspection schedule Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 5 11.5.7 Position measuring system Disposal 12.1 Environmental protection Extension and conversion Troubleshooting 14.1 How to proceed for troubleshooting 14.2 Oil cleanliness 14.3 Fault table Technical data Annex 16.1 Address directory Alphabetical index RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 6: About This Documentation

    Hydraulic fluids based on mineral oils and related hydrocarbons 90220 Data sheet General operating instructions for hydraulic power units and hydraulic 07009-B Operating instructions assemblies 2/2 directional seat valve, direct operated, with solenoid actuation, type 18136-20 Data sheet KSDE Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 7: Representation Of Information

    Type and source of hazard! Consequences in the case of non-observance ▶ Measures to avert the hazard ▶ <List> • Warning symbol: draws attention to a hazard • Signal word: identifies the degree of hazard RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 8: Symbols

    Operator software WIN-PED® 6 or WIN-PED® 7 for the HNC100 WIN-PED project Data directory in which the software data of the HNC100 are saved WinView Program for visualizing recorded variables in conjunction with WIN-PED® Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 9: Abbreviations

    Position under Plate SYEPS Electrohydraulic Punch System Supply voltage Undervoltage Verband der Elektrotechnik, Elektronik und Informationstechnik (Association for electrical, electronic and information technologies) WIN-PED® Windows Programming, Editing and Diagnosis software for the HNC100 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 10: Safety Instructions

    Any use other than described in the section “Intended use” is considered as improper and is therefore not permitted. For damage resulting from improper use, Bosch Rexroth AG will not bear liability. The risks arising from improper use lie exclusively with the user.

  • Page 11: Personnel Qualification

    Internet at: http://www.boschrexroth. 2.5 General safety instructions • The circuits proposed by Bosch Rexroth do not imply the assumption of technical responsibility for the system. • While SYEPS punching systems are being commissioned or serviced, unforeseeable risks may arise from the machine.

  • Page 12: Product-Specific Safety Instructions

    Mount the punching system completely in accordance with the installation instructions using suitable mounting equipment. ▶ Mount the punching system exclusively on suitable mounting surfaces. ▶ Observe the tightening torques and bolt strengths. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 13 Risk of injuries, crushing, getting caught due to improper hydraulic activation and unexpected startup. ▶ Take account of safety functions when engineering the punching machine! ▶ If necessary, provide light barriers or safety guards. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 14 Risk of injury! Risk of getting caught and crushing due to slow lowering of the piston rod under its own weight while the machine is switched off and depressurized! ▶ Secure the relevant area against interventions and access. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 15: Personal Protective Equpment

    See Chapter 9.1 “Switch-on sequence” on page 81 and 9.4 “HNC100 error messages - error handling” on page 108. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 16 The LED is green to signal that the voltage supply of the HNC100 is ok. The LED is green to signal that the HNC100 has been initialized and the firmware is running. The LED is green to signal that the connected Profibus works properly. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 17: General Notes On Damage To Material And The Product

    Hydraulic fluid is detrimental to the environment! Hydraulic fluid leakage leads to environmental pollution. ▶ Remove any leakage immediately. ▶ Dispose of the hydraulic fluid according to the national regulations in your country. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 18: Scope Of Delivery

    SYEPS-1X/1200-040-030-1-1 Table 7: Scope of delivery of “High“ variant for 30 t Material no. Description Term Data sheet R901251917 Punching axis SYEHL -2X/1200-040-030-1-1 RE 30200 R901121772 Digital axis control SYHNC100-NIB-1-3X/P-I-00/000/A587 RE 30139 Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 19: Advanced

    Material no. Description Term Data sheet R901251601 Punching axis SYEHL -2X/0900-040-030-2-1 RE 30200 R901121772 Digital axis control SYHNC100-NIB-1-3X/P-I-00/000/A587 RE 30139 R901205756 Electrical amplifier VT-VRRA1-527-2X/V001 RE 30045 1834486001 Card holder VT3002-1-2X/32F RE 29928 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 20: Standard

    Table 12: Scope of delivery of “Standard 750“ variant for 30 t Material no. Description Term Data sheet R901304615 Punching axis SYEHL -2X/0750-040-030-3-1 RE 30200 R901306229 Amplifier VT-MSFA1-150-1X/V0 RE 30260 R901134614 Digital axis control VT-HNC100-1-3X/P-I-00/000 RE 30139 Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 21 Phoenix Mini Combicon 3-pin R901134861 Phoenix Mini Combicon 12-pin R900218443 HD-SUB 15-pin R900218443 HD-SUB 15-pin ▶ Inspect the scope of delivery for completeness. ▶ Inspect the scope of delivery for any transport damage. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 22: About This Product

    Profibus. Other field bus interfaces are available on request. The integrated failsafe functionality allows safe operation also in emergency situations (see Chapter 2.8.1 “Safety function” on page 15 and 9.2.9 “Failsafe operationon“ on page 92. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 23 To achieve maximum punching rates, the power unit and piping must be optimized to suit the punching axis. Bosch Rexroth offers an optimally matched power unit for every axis variant. Please contact our sales organization, if you have queries regarding the hydraulic engineering of an NC punching machine.
  • Page 24 Operating range 70 to 80 (typ. 80) Low pressure LP Route the tank line and the D-line without narrowings and without any throttling points to the tank. See Chapter 7.3.1 on page 24. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 25: Digital Axis Control Hnc100

    Position PTE reached Inc. encoder +5 V Position POP reached Position PUP reached Ready Pressure A-side cylinder Pressure A-side cylinder Enable Start stroke Shield +24 V Fig. 4: Pinout SYHNC100-NIB-1-3X/... variant “Advanced“ RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 26 With variant “Standard”: Enable input Low: The punching axis moves to the upper positive stop and references the incremental position transducer. Errors are cleared with a falling edge 1 → 0. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 27 0 and +10 V. Typical values are 3.9 V for 80 bar or 7.0 V for 290 bar. Position PTE reached – OUT1 Digital outputs This output changes over to High, when the actual position value is within the position window of the axis’ PTE position. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 28: Functional Description

    The SYEPS punching systems are configured in different performance classes and can be switched between different operating modes such as punching/nibbling, engraving/marking, soft punch and deep drawing. A detailed description can be found in Chapter 9 “Operation” on page 81. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 29: Identification Of The Product

    High-response valve with proportional pilot Punching force (for up to 900 strokes/min) = 020 200 kN (20 t) Pilot operated on/off valve (for up to 750 300 kN (20 t) = 030 strokes/min) RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 30: Transport And Storage

    • Make sure that the load carrying capacity of the lifting gear is sufficient for transporting the SYEPS punching system without any risks. • Use textile slings according to DIN EN 1492-2. For further information on transportation, please contact Bosch Rexroth. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 31: Storing The Syehl Punching Axis

    Fig. 7: Lifting the SYEHL punching axis out of the packaging Transport damage must be reported to your contact in the Bosch Rexroth sales organization within one week. The addresses of sales subsidiaries can be found on the Internet at: http:www.boschrexroth.com/addresses 6.1.3...

  • Page 32: Transporting And Storing The Hnc100 And Electronics

    Proceed as follows in order to prepare the HNC100 for storage and further use: ▶ Only use the original packaging for storage. ▶ Comply with the admissible storage temperature range of –20 °C to +70 °C. ▶ Protect the HNC100 from dust and humidity. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 33: Installation

    • Hydraulic circuit diagram for the system (made available by the machine manufacturer) • Data sheet for the SYEHL punching axis (contains the technical data) • Order confirmation (contains the preset data of the SYEPS punching system) RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 34: Unpacking

    When installing the power unit, provide sufficient circulation of air. The machine paneling must not affect the circulation of air so that the cooling capacity would be reduced. Mount the power unit on a solid floor with sufficient load-carrying capacity. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 35: Installation Orientation And Piping Of Syehl Punching Axes

    7.3 Installation orientation and piping of SYEHL punching axes D-line T-line Frame Fig. 8: Vertical installation of the SYEPS punching system, piston pointing downwards Tank line Anchoring screws Fig. 9: Piping of the SYEPS punching system RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 36: General

    We recommend the use of the following accessories for connecting the axis control SYHNC-NIB-3X, the punching axis SYEHL and the power unit. These accessories are not included in the scope of delivery, but can be ordered separately from Bosch Rexroth: The following tables are subdivided by the SYEPS variants.

  • Page 37: Installing The Syeps Punching System

    If the material number of the SYEPS punching system is not identical with that in the order confirmation, contact the Rexroth Service for clarification, see Chapter 10.4 “Spare parts“ on page 114. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 38: Mounting The Syehl Punching Axis Mechanically

    All ports to be connected are marked with plastic plugs. An exception is the tank line port. It is plugged with an SAE plug. The LP, HP, T, Y, L and D ports (D port not on version Standard 600) must be connected. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 39 Seamless cold drawn tubes“, DIN EN 856 and DIN EN 853 Rubber hoses and hose assemblies - Rubber-covered spiral wire reinforced hydraulic type - Specification“. SYEPS variant “High“ Fig. 11: Block circuit diagram of variant “High“ RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 40 40/132 Installation Fig. 12: Punching system of variant “High“ SYEPS variant “Advanced“ Fig. 13: Block circuit diagram of variant “Advanced“ Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 41 Installation 41/132 Fig. 14: Punching system of variant “Advanced“ “Standard“ Fig. 15: Block circuit diagram of variant “Standard 750 kN” RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 42 42/132 Installation Fig. 16: Punching system variant “Standard 750“ Fig. 17: Block circuit diagram “Standard 600“ Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 43: Installing The Hnc100

    By snapping the housing of the HNC100 on a conductive mounting rail, the earth connection is established with the rear wall of the control cabinet. This constitutes the HF grounding of the HNC100. ▶ Do not use any silicone-containing sealants, adhesives or insulating agents. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 44 Motor control lines shielded and installed separately from other cables and/or output filter for motor cables. Extensive contact of the frequency converter housing to the rear wall of the control cabinet Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 45 The connection to the rear wall of the control cabinet is made via the housing and the DIN rail. Use metallized D-Sub connector housings. The cable shield must be pushed back and clamped under the strain relief. See Figure below. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 46 46/132 Installation Fig. 20: Breakout cable with 15-pin HD-SUB connector and open cable end Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 47 Installation 47/132 7.5.4.6 Pinout of High, Advanced and Standard axis Fig. 21: Pinout of “High“ axis RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 48 48/132 Installation Command value ref. 0 V Command value ±10 V Fig. 22: Pinout of “Advanced“ axis Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 49 Installation 49/132 Fig. 23: Pinout “Standard“ axis RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 50: Wiring Of High-Response Valve

    7.5.4.5 “Wiring of the HNC100“ on page 45. Connect the shield of the valve position transducer signal cables to neutral point Z 28. All the other connections may be installed as non-shielded cables taking account of the general wiring notes. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 51 For Advanced and Standard Mating connector with central screw: The screw must be secured by means of Loctite - NOT required with High variant. Standard Use a standard Z4 connector for connecting the high-response valve (see data sheet 08006). RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 52 M16 x 1.5 R901017011 standard “Z4“ 12...240 V Black M16 x 1.5 Length 3 m R900032020 Without circuitry, Length 5 m standard R900032014 Length 10 m R900217134 Mating connector with central screw M3x35 mm Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 53 The control coil is actuated via the 24-V output of the HNC100. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 54 Further information on mating connectors can be found in data sheet 08006. 7.5.5.2 Wiring of pressure sensors ▶ Use ready-to-connect 4-pin M12 plug-in connectors with shielded cable. Fig. 29: Ready-to-connect M12 plug-in connector, angled Fig. 30: Ready-to-connect M12 plug-in connector, straight Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 55 Ground 0 V Comm. value 0 - 10 V M- solenoid Comm. value ref. VT-MSPA1-30 Recommended cable type LiYCY 2 x 0.25 mm Fig. 32: Wiring of the pressure controller on all variants RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 56 HNC100. If the cable needs to be extended or if it is unavoidable to cut the original cable, provide optimum shielding at the place of connection. If necessary, contact Bosch Rexroth. Cable shield fixed to strain relief of...

  • Page 57: Commissioning

    If required, provide interference suppression mains filters for converters. – Ensure correct grounding. – Check cables for proper shielding. – Check that the on/off valves are properly installed and connected. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 58: Commissioning The Hnc100 And Electronics

    WIN-PED® 6 then opens the start-up screen with the project. Fig. 34: Start screen WIN-PED® 6 Double-clicking on the project shown will lead you to an overview of the individual program parts. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 59 You will be guided through the installation and can also make a language selection German/English for the program. Open the program WIN-PED® 7. First, the start page of “WIN-PED Project“ will open. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 60 3.5.0.0 and confirm your selection by clicking “OK“. The integration of WinView is now completed. To get to the overview screen for the individual program parts, double-click on the project. The following screen will appear: Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 61 Projects created with WIN-PED® 6 are not compatible with projects from WIN- PED® 7. Automatic converting is impossible, but the projects can be adjusted manually. When entering values in WIN-PED® you always have to enter a point as decimal separator. Example: 3.000 V. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 62 Fig. 38: Setting of the Profibus address The baud rate determined by the DP master is automatically recognized by the HNC100. In conjunction with Profibus-DP the existing baud rate switch is irrelevant. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 63 ← HNC100) must be transmitted first, then the output words (PLC → HNC100). For checking the data transmission from the HNC100 to the PLC, the program part “Diagnosis” in WIN-PED® must be open, the communication switched to “online“ and the diagnosis window open. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 64 Data word (2nd data word from the PLC to the HNC100) R521 “HPmax command value”: This value should only be overwritten after consultation with Bosch Rexroth. Data word (3rd data word from the PLC to the HNC100) R423 “POP1(OT)”: This data word transmits the position over plate POP (OT) with 2 decimal places.

  • Page 65: Inspecting Piping And Wiring

    This provides an oil cushion that prevents damage to the accumulator bladder. Before filling in the oil, discharge the accumulator on the gas side by opening the gas valve. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 66 66/132 Commissioning Recharging nitrogen For charging the accumulator, use the Bosch Rexroth charging and testing device (see data sheet 50170). Observe the details given in the operating instructions 50150-B and 50710-B. 2000 1000 3000 psi/ in 3600 Fig. 40: Connection of charging and testing device...
  • Page 67 Connect a pressure gauge to test port MND1 for the low pressure accumulator side (diaphragm-type accumulator) and to test port MHD1 for the high pressure accumulator (bladder-type accumulator) by means of a hose. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 68: Mounting The Flushing Valve

    This Important: The means, not in the cold condition, because otherwise the pressure values set on the controllers of the A10 pump would drift away until they reach operating temperature Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 69: Commissioning The Power Unit

    HP and LP will rise from 30 bar to ≈60 bar. Increase the value of R parameter R522 “HPmin command value“ until 85 bar is shown on the HP pressure gauge (≈3.9 Volt). Note this value as “HPmin RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 70: Referencing The Axis

    The upper positive stop must be at 40.000 mm, the lower at -0.200 mm. The position tolerance of the lower positive stop is ±0.2 mm. The upper positive stop has a tolerance of ±0.01 mm. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 71: Checking The Position Control

    According to old standard: NAS 1638, cleanliness class ≤ 7 According to new standard: ISO 4406, cleanliness class ≤ 18/16/13 If these values are not adhered to, the Bosch Rexroth warranty becomes void. To minimize the flushing time, use an oil cleanliness measuring device (particle counter) which is suitable for determining the oil cleanliness online.

  • Page 72: Removing The Flushing Valve And Mounting The Original Pilot Valve

    MND and MHD/MP to check that the system is really depressurized. When mounting the pilot valve, see to it that the mounting screws are tightened crosswise applying the correct tightening torque as specified on the installation drawing. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 73: Adjusting The Zero Point Of The High-Response Valve

    <±0.010. High Fig. 42: High-response valve STW243 Advanced Enable LED green LED red < U Zero point adjustment – zero valve –U Lvdt LED Yellow Cable break Fig. 43: VT-VRRA 1 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 74: Testing The Machine Functions

    MND must not fall below 60 bar. The following figures show reference strokes for the individual SYEPS punching systems: Fig. 44: Operating mode 34, idle stroke 3 mm with variant “High“, 20 t Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 75 Commissioning 75/132 Fig. 45: Operating mode 34, idle stroke 10 mm with variant “High“, 20 t Fig. 46: Operating mode 35, idle stroke 10 mm with variant “High“, 20 t RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 76 76/132 Commissioning Fig. 47: Operating mode 37, stroke 1 mm with variant “High“, 20 t Fig. 48: Operating mode 34 - idle stroke 3 mm with variant “Advanced“, 20 t Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 77 Commissioning 77/132 Fig. 49: Operating mode 34 - idle stroke 10 mm with variant “Advanced“, 20 t Fig. 50: Operating mode 35, idle stroke 10 mm with variant “Advanced“, 20 t RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 78 78/132 Commissioning Fig. 51: Operating mode 37, idle stroke 1 mm with variant “Advanced“, 20 t Fig. 52: Operating mode 34, idle stroke 4 mm with variant “Standard 750“, 30 t Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 79 Commissioning 79/132 Fig. 53: Operating mode 34, idle stroke 10 mm with variant “Standard 750“, 30 t Fig. 54: Operating mode 35, idle stroke 8 mm with variant “Standard 750“, 30 t RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 80 80/132 Commissioning Fig. 55: Operating mode 37, idle stroke 4 mm with variant “Standard 750“, 30 t Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 81: Operation

    CNC/PLC OUT7 Zero point Standard only *) With the high-end axis the pump command value for HP is activated and deactivated together with the command value for LP Fig. 56: Switch-on sequence RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 82 Pressure controller HP active ER command value High pressure/low pressure reached IN1 enable CNC/PLC Valve enable Accumulator discharge CNC/PLC valve item 1.72 Failsafe valve item 1.20 Standard only Fig. 58: Emergency stop Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 83: Boot Mode

    An exception is operating mode 32; in this mode the axis is always in position PTE independently of the status of the IN4. When the enable IN1 is withdrawn, the axis moves to the upper mechanical stop. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 84: Operating Modes

    The operating modes can be set via the PLC input/output signals or over field bus from the higher-level control. More information can be found in Chapter 9.3.2.1 “Description of R parameter”, section “New mode - 454” on page 100. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 85: Coordinate System Of The Syeps Punching System

    When the tool spring is completely released, the punching tool is retracted again in the stripper. The spring of the stripper pushes the stripper with the punching tool upwards until the cylinder comes to a standstill in the position above the metal sheet. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 86 In this operating mode, the cylinder moves to “Position Tool Exchange”, PTE. This position is, in most of the cases, slightly below the upper positive stop of the cylinder. Position PTE, R parameter R422, can only be adjusted by means of the Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 87: Setup (Open-Loop Controlled Operation)

    The positions POP (R423) and PUP (R425) are variable R parameters and can be set from the PLC over Profibus. For more details, please see Chapter 9.3.5. “Data transmission“ on page 105. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 88: Engraving/Marking

    “valve stroke limit”. From PSP2 to PUP the punching axis moves at the velocity set with R446 “soft punch ramp”. Back from PUP to POP the axis moves at the velocity set with R420 “positive ramp gradient”. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 89: Forming Operating Modes

    The material requires this dwell time for flowing. This helps to achieve optimum forming or embossing results. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 90: Bottom Stroke (Advanced/High Variants Only)

    The forming time set in R453 is started only after the start signal IN2 was withdrawn. The downstroke velocity can be set by means of R parameter 421. A value of 200 mm/s for R421 NRG is the optimum value for most of the applications. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 91 In this way, metal sheets can be machined that are larger than the maximum travel of the X-axis. This function can also be selected for machining metal sheets with a wheel. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 92: Failsafe Operation

    PLC outputs dropped out and the IN1 on the HNC100 is consequently at Low level. Standard The axis moves at the preset velocity of 300 mm/s to the upper mechanical stop. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 93: Energy-Saving Mode

    This value can be established during commissioning and entered in R parameter R521 “HPmax command value”. This R parameter can be optimally and dynamically adjusted to the required punching force over Profibus. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 94: Configuration

    To be able to change machine data you have to go online with WIN-PED® and in the window “Punch Control 3x...” click on the box “Machine data” or on the associated icon in the icon bar on the left. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 95 CPU card. Click the button S1 in the window “Change machine data” to open the window “Global (AO) Slot card 1 (S1) Settings” for the configuration of slot card 1. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 96 Open the dialog window “S1 Digital encoder” under the selection “Slot card 1” and select the desired encoder type in the drop-down menu “S1.ENC“. Then select the direction of the encoder and enter its resolution. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 97: R Parameters

    Fig. 72: R Parameters in WIN-PED® 6 The R parameters are subdivided into four groups per axis. The associated windows can be opened by means of buttons in the R-parameter overview window RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 98 The unit of the value is always given in square brackets at the end of the parameter designation. If no unit is specified, the value is displayed in digits. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 99 In the operating mode “punching”, the limitation is active only when moving downwards. In the operating mode “soft punch” the limitation is active between the positions PSP and PSP2. With “soft punch with pressure feedback” the RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 100 Min. pressure value of the HP pump. This pressure is present when the axis is in its - 522 rest position above the metal sheet. How to establish the value is described in Chapter 8 “Commissioning”. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 101: Process Variables

    The process variables can be selected in Diagnosis and Measurement and assist in the optimization of the system and in troubleshooting. Fig. 74: Process variables window in WIN-PED® 6 Fig. 75: Process variables window in WIN-PED® 7 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 102 Current position command value. The position command value depends on the Position command value operating mode and on the cycle step, in which the HNC100 currently is. Actual position value Current actual value of the cylinder position. Control deviation. Control error Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 103: Measurement

    Controller output value of the HNC100. Corresponds to the signal at the analog output of the relevant axis. 9.3.4 Measurement Apart from process variables, further parameters can be recorded in “Measurement”: Fig. 77: Selection of parameters to be recorded in WIN-PED® 6 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 104 2, etc. AO stands for Analog Output. S1.AO.1 is analog output 1 of slot card 1. The control loop value of the axis is assigned to output S1.AO.1, the pressure command value of the high-pressure pump to output S1.AO.2. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 105: Data Transmission

    Profibus protocol in the HNC project made available to you. It is possible to transmit data during a cycle. The data are, however, only taken over after the cycle is completed. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 106 HNC100 Bus manager. 32 bytes can be sent by and to the HNC100. Table 29: Data from the HNC100 Data word A-variable Decimal places Meaning Acknowledge bits Profibus Error bits Profibus A002 Error A001 Actual position value A003 Operating mode A004 Following error(k) Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 107 To generate this hardware configuration you have to read in the GSD file of the HNC100 to the programming system of the PLC. You can download the GSD file from the Web page http://www.boschrexroth.com/hnc100 . Fig. 80: Configuration example of an S7-400 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 108: Hnc100 Error Messages - Error Handling

    R 460 = 0. This action also switches off the automatic compensation for drift and wear-related control errors. 26-41 Bosch Rexroth Internal HNC error Inform Bosch Rexroth Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 109 1) For warming up, switch the power unit on and feed forward command values to the LP and HP pumps. Then de-energize accumulator discharge valve item 1.170 type KSDER1PB/HN0V and let the power unit run for about 20 min. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 110: Maintenance And Repair

    Item to be inspected/serviced Inspection/maintenance work Initially Subsequently Hydraulic system Inspect for leakage Hydraulic system Check for generation of noise Hydraulic power unit Check oil level Hydraulic power unit Check operating temperature Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 111: Inspection For Leakage

    The precharge pressure p0 indicated on the circuit diagram or on the accumulator label must be set after each installation or after repairs and then be checked at least RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 112: Oil Analysis

    Should the hydraulic power unit be dirty after handling or storage, clean the oil fill connection on the reservoir before opening it. Never remove strainers from the filling connection or the filter insert of filters when filling in the fluid. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 113: Open-Loop-Controlled Operation Of The Punching Axis With Test Box Vt-Vet In Conjunction With Variant "High

    By turning the potentiometer “setpoint“ (8) you can extend and retract the cylinder. 10.3 Repair Rexroth offers a comprehensive range of services for repairing SYEPS punching systems. The SYEPS punching system may be repaired exclusively by authorized, trained and instructed personnel. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 114: Spare Parts

    POSITION TRANSDUCER BAV-P-PH-00028-01 * Position measuring system 1.62 R900769274 DBDS 10 K1X/330VE 25402 Pressure relief valve 1.70 R901083196 KSDER1PB/HN0V 18136 Pressure discharge valve 1.72 R900991121 COIL GZ37-4 24VDC 22W 18136 Coil of pressure discharge valve Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 115 Coil of pressure discharge valve 1.80 R901296640 HM20-1X/250-C-K35 30270 Pressure transducer Alternative for China: R901256158 HAD2,0-350-2X/0G05E05-1N111-CHN R901344198 HAD2,0-350-2X/0G05E05-1N111-SELO The correct replacement of spare parts is described in Chapter 11.5 “Replacing components“ on page 116. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 116: Demounting And Replacement

    When replacing valves intended for subplate mounting, the screws can no longer be secured against loosening by means of Loctite 243, because the threaded bore fills with oil and the removal of glue residues involves a great risk of damage. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 117: Pilot Valve Stw243 (High), Stw365 (Advanced); H-4Weh (Standard)

    Lever the high-response valve out from the cartridge bore at the 4 grooves of the corners of the housing. When installing the new valve, pay attention to the position of the locating pin. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 118: High-Response Valve Advanced Stw365

    To reduce the flow: Turn the stroke limiting screw clockwise. To increase the flow: Turn the stroke limiting screw counter-clockwise. Tighten the locknut to a tightening torque of ±30 Nm. After having tightened the locknut, recheck the velocity. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 119: Lp Accumulator

    Traverse the punching axis at low speed in open-loop-controlled operation in operating mode 33 to check whether the 1-mm gap between the measuring head and the measuring tape remains constant. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 120 11.5.7.4 Pressure sensor HM20 When installing the valve, observe the correct tightening torque, which can be found in the installation drawing, and make sure that the seal is properly installed. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 121: Disposal

    Chapter 11.5 “Replacing components“ on page 116. The punching system SYEPS can be extended with HM16 pressure sensors for monitoring system pressures and the adaptive soft punch function. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 122: Troubleshooting

    The indicators can also respond at low oil temperatures. For this reason, the indication should only be evaluated after the hydraulic system was in operation for 5 to 10 minutes. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 123: Fault Table

    Check and, if required, correct, connection cables. Accumulator discharge valves not closed Check accumulator discharge valves and close them, if open. Accumulator charging valve is not actuated Check function and actuation of the accumulator properly charging valve. RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 124 WIN-PED®. Limiting cycles are present, when the actual value fluctuates around the target position at low frequency and the valve tries to correct this in vain. The cylinder shows excessive friction and must be replaced. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 125 800 to 1000 Hz) at 800 to 1000 Hz“ Measurement data acquisition in Trigger condition and level incorrectly set Correct trigger conditions WIN-PED® does not trigger Measurement not activated Activate RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 126: Technical Data

    Error in the PLC program – an impermissible Correct PLC program. transmitted over Profibus, the value is transmitted. HNC100 issues the error message “impermissible operating mode”. 15 Technical data The technical data can be found in data sheet 30200. Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...

  • Page 127: Annex

    Tel. +49 (0) 93 52 - 18-0 info@boschrexroth.de applications-centre@boschrexroth.de or the sales organization Contacts for repairs Service Hydraulics Bgm.-Dr.-Nebel-Str. 8 97816 Lohr am Main Tel. +49 (0) 9352 - 40 50 60 service@boschrexroth.de http://www.boschrexroth.com/service RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...

  • Page 128: Alphabetical Index

    Data transmission Hydraulic connections Demounting and replacement Digital axis control VT-HNC100 ▶ I – analog inputs Identification of the product – analog outputs Improper use – digital inputs Incremental position transducer Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 129 – general Personal protective equpment – product-specific Pinout Scope of delivery Place of installation of HNC100, valve – Advanced amplifiers and amplifier modules – High Position tool exchange - 32 – Standard RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 130 ▶ U Unpacking ▶ V Visual indicators Voltage supply ▶ W WIN-PED® – installation Wiring – high-response valve – incremental position transducer 56 – on/off valve – pressure controller – pressure sensors Bosch Rexroth AG, SYEPS series 1X, RE 30201-B/07.2014...
  • Page 131 Alphabetical index 131/132 RE 30201-B/07.2014, SYEPS series 1X, Bosch Rexroth AG...
  • Page 132 Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Tel. +49 (0) 9352 18-0 info@boschrexroth.de www.boschrexroth.com Subject to revision Printed in Germany RE 30201-B/07.2014...

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