Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Test unit VT-PDFE-1X... RE 29 689-B/01.03

for closed-loop control systems

SYDFE

Operating instructions
2

© 2003
by Bosch Rexroth AG, Industrial Hydraulics, D-97813 Lohr am Main
All rights reserved. No part of this document may be reproduced or stored, processed, duplicated or circulated using electronic
systems, in any form or by any means, without the prior written authorisation of Bosch Rexroth AG.
In the event of contravention of the above provisions, the contravening party is obliged to pay compensation.
VT-PDFE-1X...

Table of contents

1 Table of contents
1 Table of contents............................................................................................................... 3
2 Structure and operating principle of the test unit .......................................................... 4
2.1 General ......................................................................................................................... 4
2.2 Block circuit diagram ..................................................................................................... 5
2.3 Electrical connections.................................................................................................... 6
2.3.1 General guidelines................................................................................................................................6
2.3.2 Supply voltage ......................................................................................................................................6
2.4 Front of the test unit ...................................................................................................... 7
2.4.1 Voltage supply ON / OFF .....................................................................................................................7
2.4.2 Internal / external command value feedforward ...................................................................................7
2.4.3 Measuring points ..................................................................................................................................8
2.4.4 Signal lamps .........................................................................................................................................8
2.4.5 Potentiometers .....................................................................................................................................9
2.4.6 Jumpers................................................................................................................................................9
3 DFE system...................................................................................................................... 10
3.1 Operating principle ...................................................................................................... 10
3.2 Control system supply ................................................................................................. 11
3.3 Block circuit diagram for the control electronics VT-DFP-1X and VT-DFPE-2X.......... 12
3.4 Pin allocation of the central plug ................................................................................. 13
3.5 Functional description of the signals to the central plug.............................................. 14
3.6 Connection of the pressure transducer ....................................................................... 15
3.6.1 General...............................................................................................................................................15
3.6.2 HM12 ..................................................................................................................................................15
3.6.3 HM13 ..................................................................................................................................................15
3.7 Guidelines to be taken into account ............................................................................ 16
4 Possible adjustments on the SYDEE system ............................................................... 17
4.1 Adjustment of the system pressure ............................................................................. 17
4.1.1 Adjustment of the pressure command value......................................................................................17
4.1.2 Adjustment of the actual pressure value ............................................................................................18
4.2 Checking the swivel angle measurement .................................................................... 19
5 Error diagnosis on the SYDFEE system ....................................................................... 20
5.1 Reasons for the presence of an error message .......................................................... 20
5.1.1 Error in the actual pressure value branch ..........................................................................................21
5.1.2 Error in the actual swivel angle value branch .....................................................................................22
5.1.3 Excessive system deviation of the pressure or swivel angle controller..............................................23
5.1.4 Excessive temperature.......................................................................................................................23
5.1.5 Other error messages ........................................................................................................................23

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Structure and operating principle of the test unit

2 Structure and operating principle of the test unit

2.1 General
This test unit was designed primarily for the closed-loop control systems
SYDFEE-1X... and SYDFEE-2X.... It can be plugged like an extension cable into
the incoming cable of the VT-DFP-1X... or VT-DFPE-2X high-response valves. All
the signals fed to and from the pilot valve can be measured at measuring sockets
(2mm) and then evaluated. In this way, a diagnosis can quickly be carried out in
case that problems occur in conjunction with the pump system.

In principle, the following applications are conceivable:

− The unit serves as intermediate adapter and is exclusively used to make all
the signals measurable that are exchanged between the SYDFEE.. system
and the higher-level control.
− In addition to the function explained above, the unit assumes the task of
generating command values for pressure and swivel angle.
The command values of swivel angle and pressure are selected by means of
a ten-turn potentiometer, which allows command values of 0 to ca. 120 % to
be generated.

Caution:
Before utilizing this function make sure that the system is in an
operationally safe state so that in the case of an improper selection of
command values damage to the machine and personal injury can be
ruled out.

Note:
These instructions provide notes and assistance which refer exclusively to
SYDFEE-1X and SYDFEE-2X systems. Should the unit be used for other
components, we cannot assume a functional warranty for the test unit or the
relevant component.

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Structure and operating principle of the test unit

2.2 Block circuit diagram

The block diagram is shown also at the back of the test unit.

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Structure and operating principle of the test unit

2.3 Electrical connections

2.3.1 General guidelines

The test unit is fitted with a socket and a plug-in connector to loop it in in the
incoming cable to pilot valves VT-DFP-1X... or VT-DFPE-2X... of the SYDFEE...
pump system. The socket is plugged directly onto the pilot valve of the pump unit,
the plug-in connector is to be connected to the incoming cable of the pilot valve,
which was disconnected beforehand. The plugs cannot be interchanged.
− The pilot valve has no enable input to enable or disable the control function of
the valve. The closed-loop control becomes effective as soon as the pilot
valve is energized and the pump is powered. The command values fed
forward are decisive for the operational states of pressure or swivel angle
control.
− The contacts in the plug-in connector must not be subjected to mechanical
loads. This can cause temporary or permanent damage to the connection
between the connection box and the component plug.

2.3.2 Supply voltage

The test unit has no own voltage source and uses the supply voltage of the pilot
valve for its own supply.
For operating the pump system, an external voltage supply is required as is the
case without this test unit.
The voltage supply to the pilot valve can be switched on and off with switch UB on
the test unit. When the supply voltage is applied and switch UB is operated, the
green LED next to it lights up, signaling that voltage is applied to the pilot valve.

The test unit is not fitted with any electrical fuses (e.g. back-up fuse) against
overcurrent; this is valid for both, the led-through voltage supply and signal
cables. Fuses must be provided on the system side.

In the case of a fault or when work has to be carried out, the pilot valve can be
de-energized using switch UB.

Caution: In the case of systems with external supply, the safety function,
which swivels the pump from zero stroke when the control valve is de-
energized, is not effective. Here, it is recommended that in the case of a
fault the drive motor of the pump be switched off as well!

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Structure and operating principle of the test unit

2.4 Front of the test unit

2.4.1 Voltage supply ON / OFF

Switch UB can be used to interrupt the voltage supply to the pilot valve.
The greed LED next to the switch signals that the supply voltage is applied and
the switch is operated. In this case, voltage is supplied to the connected pilot
valve.

2.4.2 Internal / external command

value feedforward
This switch can be used for selecting the signal source for the command values
for “pressure” and “swivel angle” of the pump system.
The following determination is valid here:
− Position INTERN (= potentiometer)
At this switch position, the command value is taken from the two
potentiometers installed in the test unit and fed to the output plug of the unit.
The command values are fed exclusively from the test unit to the pilot valve or
to the pump system. In this case, any connected higher-level control has no
influence on the command value feedforward to the pump system.
− Position EXTERN (= external control)
At this switch position the command value is fed from the input plug of the test
unit directly to the output plug of the component. This means that the higher-
level control takes over the command value for the pilot valve or the pump
system. The test unit merely serves as measuring point for all signals.

The switch always causes a changeover of both command values to the relevant
source.

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Structure and operating principle of the test unit

2.4.3 Measuring points

All the signals of the test unit are brought out via 2mm measuring sockets and
can be measured using suitable measuring instruments or an oscilloscope.

The following must be observed here:

− Reference for the voltage supply (socket "UB") as well as for socket "switch
TD" and "Fehler" is socket "L0".
− Reference for the "pist High" signal is socket "pist Low".
− Reference for all the other variables to be measured is socket "M0".
− Depending on the variant of the pilot valve, socket "switch TD" can be a digital
input ("switch TD") or a digital output ("LB active").

No connections may be established between the measuring sockets, since

this could lead to short-circuits, malfunction or other defects!

2.4.4 Signal lamps

2.4.4.1 Green LED (UB)

When the supply voltage is applied and switch UB is operated, this is signaled by
the greed LED next to the switch. In this case, voltage is supplied to the
connected pilot valve.

2.4.4.2 Red LED (error)

An LED next to the measuring socket for the “Fehler” (error) signal shows the
current status of the error message. The switching signal is output by the pilot
valve and operates according to the logic principle of "low-active".
i.e. - signal level 0V (or more precisely <1V) signals an error
- signal level +24V (or more precisely >13V) signals no error

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Structure and operating principle of the test unit

2.4.5 Potentiometers
The test unit comprises two 10-turn potentiometers for the selection of a
swivel angle command value (alphaSOLL) and a pressure command value
(pSOLL). They are only activated when switch "Sollwertvorgabe" (command
value selection) is turned to position "intern".
The adjustment range of the two potentiometers is from 0V to
approx. +12V and can be set exactly to the requested command value.
The voltage output can be measured at the two measuring sockets
(alphaSOLL and pSOLL / reference M0) situated directly below.

2.4.6 Jumpers
The jumpers can be used to separate the actual pressure value signal that is fed
to the pilot valve via the central connecting cable. The jumpers are included in the
scope of supply of the test unit.
The actual pressure value level (PISTH) is fed to the pilot valve with its own
reference potential (PISTL). The lower pair of measuring sockets is connected to
the connections of the higher-level control, from where the signal of the pressure
transducer comes. The upper pair of sockets is constantly connected to the pilot
valve on the pump unit.

None of the jumpers may be unplugged while the closed-loop pump control
is active, since otherwise no current actual pressure value signal is fed to
the pump control and thus, impermissible operating conditions could
occur.

When the jumpers are unplugged, an actual pressure value signal from another
pressure transducer can be fed to the valve, if required.
In this case, the pressure signal must be connected to the upper pair of sockets
(according to SYDFEE). It is important that both, the signal (pISTH) and the
reference (pISTL) are connected.

For normal operation, the two jumpers must always be plugged.

Exception: When the integrated HM16 pressure transducer is used, which

is connected directly to the pilot valve, the connecting plugs have no
influence.

Suggestion:
If you replace one of the two jumpers by looping in an amperemeter, the output
signal can be measured directly, e.g. in the case of pressure transducers with
current output.

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DFE system

3 DFE system

3.1 Operating principle

The closed-loop pressure and swivel angle control for an A10VSO variable
displacement pump of the SYDFEE system is via an electrically controlled
proportional valve (2). The proportional valve determines the position of a
swashplate (1) via actuating piston (4). The displaced flow is proportional to
the position of the swashplate. A counter-piston (3), which is preloaded by a
spring (5), is permanently pressurized with pump pressure.
When the pump does not rotate and the control system at zero pressure,
the swashplate is held in position +100 % by the spring (5).
With a driven pump and a de-energized proportional solenoid (8) the
system regulates to zero stroke pressure as the valve spool (9) is pushed to
the initial position by the spring (10) and, therefore, pump pressure p is
applied to the actuating piston (4) via valve port A.
A balance between the pump pressure at the actuating piston and the
spring force (5) is achieved between 8 to 12 bar. The pump swivels to its
initial position (= zero stroke operation) when, for example, the valve
electronics is de-energized.
Controlling of the proportional valve is assumed by the analog electronics
(11), which is integrated into the valve. The closed-loop control electronics
processes all of the control signals required to operate the A10VSO
variable displacement pump in the closed-loop pressure and flow control
mode. The closed-loop control electronics has separate command value
inputs for pressure and swivel angle via the central plug (12); for the
optional power limitation, the command value can be adjusted with the help
of an internal potentiometer.
The HM16 pressure transducer is connected to port P of the pump or, if the
SYDZ pre-load valve is fitted, to port MP1 and to the M12 component
socket (13).
Alternatively, an external pressure transducer can be connected via the
central plug (12). A position transducer with integrated electronics (7) fitted
on the pump establishes the actual swivel angle value.
The measured actual values are processed in the amplifier and compared
with the given command values. The minimum value generator ensures
that automatically only the controller is active that is allocated to the
required working point. Thereby, a system variable (pressure, swivel angle
or [optional] power) is exactly corrected, while the other two values are
below the given command values.
The output signal of the minimum value generator becomes the command
value for the valve control loop.
The actual value for the valve spool position is sensed using an inductive
position transducer (6). The output value of the valve position controller
defines, via the amplifier output stage, the current through the proportional
solenoid (8).
As soon as the working point is reached the proportional valve control
spool (9) is held in the central position.
If the higher-level controllers demand an increase of the swivel angle
(increase in flow), then the valve spool (9) must be moved from the central
position (connection of the actuating piston (4) A to T) until the swivel angle
has reached the required value.
The movement of the valve spool against the force of the spring (10) is
achieved by increasing the electrical current through the proportional
solenoid (8) accordingly. The reduction of the swivel angle (reduction in
flow) is achieved by connecting the actuating piston (4) from P to A.

For further information, see RE30030.

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DFE system

3.2 Control system supply

There are three ways of supplying the pump‘s hydraulic control system
with pilot oil:
1. Internal, without pre-load valve (only possible for system pressures >20bar)
With this circuitry variant, system pressures below 12bar are not realized. If
the flow must be controllable at a working pressure of less than 12bar or if a
pressure < 12bar is to be controlled, this is possible through the use of a pre-
load valve or external supply to the actuating system.
2. Internal, with pre-load valve (system pressures 0 …100%)
3. Remote supply via a shuttle valve – automatic switchover internal /external
via a shuttle valve sandwich plate.

Notes on the operation with external supply:

• With an external supply of the control system the feature that

swivels the pump to the zero stroke position when the control
electronics are de-energized is deactivated.
• With de-energized control electronics the control pump’s
swashplate is pushed onto the negative stop through the external
pressure (100 % of the flow is passed to tank).
• Command values for pressure and flow must always be greater than
zero (pressurecom >3 bar, swivel anglecom >5 %), as, due to drift or
inaccurate setting, no exact “zero“ pressure or “zero” swivel angle
exists. Smaller command values can lead to cavitation under
unfavorable conditions.
• The actual pressure value must not be lower than 10 bar for more
than 10 minutes (lubrication)!

For further information, see RE 30 030-01-B

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DFE system

3.3 Block circuit diagram for the control

electronics VT-DFP-1X and VT-DFPE-2X

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DFE system

3.4 Pin allocation of the central

plug
The central plug is the only electrical connecting element between the SYDFEE
pump system and the control. The plug is to be plugged in on the pilot valve.
The table below shows the pin allocation of the plug “11 + PE” for VT-DFP-1X or
VT-DFPE-2X... valves.
The colors stated in the right-hand column refer to he optionally available cable
set.
Type: "Connection plug 11+PE, 2x5m" (Mat. no. 032356)
or 2x20m (Mat. no. 860399)

Cable color or
Pin Meaning Cable designation for Rexroth
thickness cable
1 UB (+24V) 1 mm² 1 1
3x1mm² 2 L0 1 mm² 2 2
Earth 1 mm² GNYE yellow/green
3 Error (=0V) 0.14 mm² WH white (beige)
4 M0 0.14 mm² YE yellow
5 αcom. 0.14 mm² GN green
6 αact. 0.14 mm² VT violet
10x 7 pcom. 0.14 mm² PK rose
0.14mm² 8 pact. 0.14 mm² RD red (orange)
9 switch TD 0.14 mm² BN brown
10 pact. high 0.14 mm² BK black
11 pact. low 0.14 mm² BU blue
- Not used 0.14 mm² GY gray (yel./green)
- Shield
The colors in brackets refer to the standard before 06/96

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DFE system

3.5 Functional description of the

signals to the central plug
Pin Signal Description direction** Signal level

+24V
1 UB Voltage supply IN
-5% +40%
2 L0 = 0V Reference potential for voltage supply - -
PE Earth connection for the electronics - -
Passes faults to a PLC; e.g. cable break,
0V: fault
3 ERROR command/actual values, controller OUT
monitoring, voltage monitoring for symmetry +24V: no fault

Reference potential for all command and

4 M0 - -
actual values
5 αsoll Swivel angle command value IN 0 to +10V
6 αist Actual swivel angle value OUT ±10V
7 psoll Pressure command value IN 0 to +10V
8 pist Actual pressure value OUT 0 to +10V
Case 1: Electronics without additional
functions
Ordering code: SYDFEE-2X/.... -AXA.. Switch TD
For electronics without additional functions,
switch TD* IN
Pin 9 is used as an input to switch over to a +24V: active
second oil volume matching of the pressure 0V: inactive
controller.
9 For further information, see RE30 030-B.
Case 2: Electronics with additional functions
Ordering code: SYDFEE-2X/.... -AXB.. Power limitation
Power For electronics with additional functions, OUT
limitation Pin 9 is an output to the PLC and signals +24V: active
0V: inactive
(+24V) that the power limiter is active.
For further information, see RE30 030-B.
Actual pressure value from pressure
transducer
Ordering code:
10 pist High* SYDFEE-2X/.... -AXXXV... IN 0-10V
SYDFEE-2X/.... -AXXXE... 1-10V
SYDFEE-2X/.... -AXXXC... 4-20mA
SYDFEE-2X/.... -AXXXD... 0-5V
SYDFEE-2X/.... -AXXXF... 0.5-5V
11 pist Low Reference potential to signal pist High - -
Connect shield of signal cable 10x0.14mm²
Shield -
to ground with one end in the control cabinet
* Signal type dependent on order, for entire ordering code, see RE 30030
** approaching from the pump

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DFE system

3.6 Connection of the pressure

transducer

3.6.1 General
In the first generation of the SYDFEE... pump control, the pressure transducer
used to be connected always via the central connection plug on pilot valve type
VT-DFP-1X... or VT-DFPE-2X... (connections 10 and 11).
A later pilot variant allows the connection of the pressure transducers (exclusively
of type HM16) directly to the high-response valve. These pilot valves can be
externally recognized by their additional plug (M12 / 5-pin) on the cast-iron cover.
This is also signaled by the highlighted letter on the nameplate.
Example: VT-PDFE-x-2X/G24K0/0A0F/V
In this case, no pressure transducer may be connected via the central plug on
connections 10 and 11.
For more details about HM16, see RE30 266.

3.6.2 HM12
The pressure transducer type HM12 is provided with a 2-wire current interface
and can be connected to the high-response valve via the central plug as shown
below.
The supply voltage for the pressure transducer must be provided in accordance
with the specification.
For more details about the pressure transducer, see RE29 933.

3.6.3 HM13
Pressure transducer type HM13 is fitted with a voltage output 0... +10V as actual
pressure value signal and can be connected to the high-response valve via a
central plug as shown below.
The supply voltage for the pressure transducer must be provided in accordance
with the specification.
For more details about the pressure transducer, see RE29 933.

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DFE system

3.7 Guidelines to be taken into

account
− RE 07 900 Assembly, commissioning and maintenance of oil hydraulic
systems
− RE 92712 Installation guidelines and further details regarding the A10VSO
pump (size 18)
− RE 92711 Installation guidelines and further details regarding the A10VSO
pump (sizes 28...140)

The VT-DFP-1X... resp. VT-DFPE-2X control valve monitors internal as well as

system-side operating conditions, it can, however, not prevent in all cases
uncontrolled movements of hydraulically connected actuators. A personnel
hazard has, therefore, to be prevented by suitable measure via the
EMERGENCY OFF CHAIN on the system side!

The VT-DFP-1X... resp. VT-DFPE-2X control valve does not have an enable
input to switch the control function on and off. In the case of a fault the control
valve power supply should be switched off. These functions should be integrated
into the system safety chain.

Caution: In the case of systems with external supply, the safety function,
which swivels the pump from zero stroke when the control valve is de-
energized, is not effective. Here, it is recommended that in the case of a
fault the drive motor of the pump be switched off as well!

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Possible adjustments on the SYDEE system

4 Possible adjustments on the SYDEE system

4.1 Adjustment of the system

pressure
The system pressure is the pressure level which the pump system is to generate
in the machine as maximum value.

The pilot valve converts the signal level of the pressure transducer connected to
the pump system to the normalized level of 0... 10V and passes this actual
pressure value on to the pressure controller.
The converted actual pressure value can be measured on the test unit at
socket pIST.
Depending on the variant of the pilot valve, the corresponding pressure
transducer signal is converted into the signal level 0... 10V (factory setting of the
system);
some examples:
- 4... 20mA is converted into 0... 10V (variant C in the type code)
- 1... 10V is converted into 0... 10V (variant E in the type code)

The pressure controller of the SYDFEE.. system compares the level at the
command value input (0... 10V) with the converted actual pressure
value (0... 10V).
If, at a maximum pressure feedforward (+10V), the measuring range of the
pressure transducer does not correspond to the system pressure, controlling will
not be based on the value of the system pressure, but on the final value of the
pressure transducer’s measuring range.

An adjustment is possible in two ways:

− Adjustment of the pressure command value
− Adjustment of the actual pressure value

4.1.1 Adjustment of the pressure

command value
In the case of an adjustment of the pressure command value, the pressure
command value is normalized to the measuring range of the pressure transducer
and fed forward accordingly.
This procedure requires no adjustment work on the pilot valve. This is favorable
in the case of pump systems that are difficult to access.
Example:
Measuring range of the
pressuretransducer: 0... 250bar
Selected system pressure: 190bar
Here, the following is valid for the
pressure command value feed forward:10V / 250bar = 0.04 V/bar (= factor)
0.04 /bar x 190bar = 7.6V

i.e. the pressure command value is normalized to the factor of 0.04 V/bar;
in order to feed the system pressure forward as pressure command value, a
pressure command value of 7.6V must be generated.

General formula:
Factor: 10V / measuring range of the PT
Pr. comm.value for a pressure: Pressure x factor = pressure command value [V]

PT= pressure transducer

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Possible adjustments on the SYDEE system

4.1.2 Adjustment of the actual

pressure value
In the case of an adjustment of the actual pressure value, the actual pressure
value is normalized in relation to the system pressure.
With the factory setting, the VT-DFPE-2X.. pilot valve converts the signal of the
pressure transducer internally to the range of 0... +10V.
You can use potentiometer R2 that is located behind a fitting in order to change
the signal range (= gain) of the actual pressure value.
Procedure for system in operation:
− Close all directional valves. There must not be any oil flow.
− Apply a swivel angle command value greater than +5V.
− The system pressure is set using potentiometer R2 which is located behind
the fitting on the housing cover (see picture below).

− The pressure command value is to be set to 5.00V (half system pressure).

After this, the potentiometer has to be adjusted until exactly half of the system
pressure is achieved. For checking purposes the maximum system pressure
has to be reached (pmax / ±3bar) with a command value of +10.0V.

Turning the potentiometer clockwise reduces the gain, i.e. the pressure level
increases.

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Possible adjustments on the SYDEE system

4.2 Checking the swivel angle

measurement
The setting of the swivel angle measurement is made in the factory. The following
setting procedure have to be carried out only if the swivel angle transducer had to
be changed,.
Depending on the circumstances, the "100%" swivel angle can be balanced while
the drive motor is in operation or at rest.

Check swivel angle "zero" (while system is in operation)

− Close all directional valves

− Apply a swivel angle command value greater than +5V
− Apply a pressure command value 20 bar
− Check to see if the swivel angle actual value is 0V ±100mV (alphaIST)
− Compensate for deviations using, potentiometer (1);
the potentiometer is marked with "O" (=Offset) on the body of the swivel angle
transducer.

Check swivel angle for "100%" (while system is in operation)

− Swivel angle command value greater than 10.5V, pressure command value
approx. 5V
− Provide actuator with full flow, e.g. control hydraulic motor or set pressure
control valve to 20 bar.
Note: In this case a fault message will be signaled by the control valve
(excessive system deviation)
− Adjust potentiometer (2) until the actual swivel angle value is +10V;
the potentiometer is marked with "G" (=Gain) on the body of the swivel angle
transducer (corresponds to max. stroke).

Check swivel angle "100%" (while drive motor is switched off)

− Switch off the hydraulic system and wait for ca. 5 min until the pump swivels
mechanically out (wait for complete pressure reduction).
− Turn potentiometer (2) until the actual swivel angle value is 10.05 V; the
potentiometer is marked with “G” (= gain) on the body of the swivel angle
transducer.
− In some cases, the pump does not swivel to the mechanical limit. For this
reason, briefly switch on the motor, switch it off again, wait until the pump has
swiveled out and then measure the actual swivel angle value. If the
measurement provides a higher voltage, correct the value.
Repeat this process several times!!

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Error diagnosis on the SYDFEE system

5 Error diagnosis on the SYDFEE system

The error message can be evaluated at socket “Fehler” (error) as well as on the
lamp indicator (central pin 3).
Here, the following is valid:
− If the high-response valve does not recognize an error, this means that the
signaling output outputs a voltage level >13V. The signaling output is
overlaod-proof. From load currents of ca. 15 mA the output voltage falls.
− If the VT-DFP-1X... or VT-DFPE-2X... valve recognizes an error, it is possible
to measure a voltage of ca. 0V at the error signaling output. (In this case, the
signaling output is connected with UB with high resistance (in the order
of M Ω)).

Meaning of the signal Output signal at pin 3

Electronics OK 24V (UB – 2V)

Error 0 to 5V

The error message of the VT-DFP-1X... or VT-DFPE-2X... high-response valve is

composed of several, internally connected error messages. The message has no
saving function, i.e. if the error is present only briefly, the message is present at
measuring socket “Fehler” (error) (pin 3 / error message) for the same period.

5.1 Reasons for the presence of

an error message
− Error in the actual pressure value branch
− Error in the actual swivel angle value branch
− Excessive system deviation of the pressure or swivel angle controller
− Temperature limit value exceeded in the housing (ca. 80°C)
− Actual valve value less than –11.5V or greater than +11.5V
− Voltage symmetry of internal voltages of the high-response valve
outside limit values

The above errors will be described in more detail on the following pages.

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Error diagnosis on the SYDFEE system

5.1.1 Error in the actual pressure value

branch
Triggered at an actual pressure value at pIST is less than –0.5V and greater than
+11.5V

The signal of the pressure transducer is normalized for the pressure controller
and converted to level 0... 10V. As soon as this internal level leaves the range
mentioned before, an error message is triggered. The internal actual pressure
value can be measured on the test unit at socket pIST.

Test:
When an error message is present, check that the voltage of actual pressure
value pactual (pin 8) is within the above working range.

If it is not, check input pins 10 (pact_High) and 11 (pact_Low) for correct connection
back to the pressure transducer (= signal source).
Valve type VT-DFP (input signal for actual pressure value: Current or voltage as
well as range) using the output signal of the pressure transducer.

Evaluation:
If the actual pressure value falls below limiting value –0.5V, the following causes
are possible:
− The connection between the pilot valve and the pressure transducer is
missing.
For example, the plug is not plugged onto the transducer, no voltage supply
available for the pressure transducer.

If the actual pressure value exceeds the limiting value of +11.5V, the following
causes are possible:
− Wiring error between pilot valve and pressure transducer
− A potentially defective pressure transducer outputs too high a level
− Signal type of the pressure transducer and the pilot valve are not identical

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Error diagnosis on the SYDFEE system

5.1.2 Error in the actual swivel angle

value branch
Triggered at an actual swivel angle at alphaIST of less than –11.5V and greater
than +11.5V.

The swivel angle transducer is supplied with DC voltage by the pilot valve and,
depending on the swivel angle of the pump, feeds a voltage value of
-5V ±3V back to the pilot valve.
This actual swivel angle value is converted by the pilot valve to a level of ±10V.
The two working points “swivel angle 0%" (alphaACT = 0V) and " swivel angle
+100%" (alphaACT = +10V) are adjusted with the help of the two potentiometers on
the swivel angle transducer before the units are dispatched.
The swivel angle used internally is within the range of
-10V for max. negative swivel angle and
+10V, for max. positive swivel angle.
This value can be measured on the test unit at socket alphaIST.

At values outside this range, an error message is triggered.

Test
When an error message is present, check whether the voltage of actual swivel
angle value alphaACT (central plug pin 6) is within the working range mentioned
before.
If it is not, check the plug-in connection on the swivel angle transducer and the
cable from the swivel angle transducer to the VT-DFP-1X... or VT-DFPE-2X...
high-response valve. If required, check the voltage supply to the swivel angle
transducer (see illustration below).

Evaluation
The following causes are possible:
− In the case of a pump control without external supply, when the drive motor is
switched off, the actual swivel value moves towards a swivel angle of +100%
due to the spring on the opposite piston of the actuating system. If, in this
case, the actual swivel angle value is greater than +10V the actual swivel
angle value must be re-adjusted, (see Checking the swivel angle
measurement on page 20).
− The plug-in connector to the pilot valve is possibly not plugged on or the
connection is defective.
− The swivel angle transducer is defective.

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Error diagnosis on the SYDFEE system

5.1.3 Excessive system deviation of

the pressure or swivel angle controller
The pilot valve monitors the valve command value continuously for the amount of
its control output. If the value remains above the amount of 40% over a period
greater than 1sec., an error message is output.
Depending on which controller has been activated by the minimum value
generator, this state is obtained in the case of the following system deviations:
− In closed-loop pressure control, system deviation more than ±1V for longer
than 1 sec.
− In closed-loop swivel angle control, system deviation more than ±0.5V for
longer than 1 sec.

Note:
This error message is also output, when, for example, the command values for
swivel angle and pressure are not adjusted to the current actual values for swivel
angle and pressure when the drive motor is switched off.

5.1.4 Excessive temperature

The pilot valve is internally fitted with a temperature sensor. If the temperature in
the housing rises to a value greater than ca. 80°C, the error message is
activated.
This error message is only possible after a longer period in operation (> ca.
20min.) and at high ambient temperatures. For testing purposes, the housing can
be cooled to rule out this error.

5.1.5 Other error messages

− Voltage symmetry of internal voltages of the high-response valve outside limit

values.
− Actual valve value less than –11.5V or greater than +11.5V
Both error messages cannot be examined in more detail locally.

RE 29 689-B/01.03 23
Bosch Rexroth AG
Industrial Hydraulics
Zum Eisengießer 1
97816 Lohr, Germany
info@boschrexroth.de
www.boschrexroth.com

Printed in Germany
RE 29 689-B/01.03