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REXROTH CytroPac User Manual

REXROTH CytroPac
76 pages
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Operating instructions
RE 51055-B/02.2021
Replaces: 06.17
English
Small power unit
CytroPac

Table of Contents

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REXROTH CytroPac Specifications

General IconGeneral
BrandREXROTH
ModelCytroPac
CategoryPortable Generator
LanguageEnglish

Summary

About this documentation

1.1 Validity of the documentation

This documentation applies to the Small power unit CytroPac, for fitters, operators, service technicians, etc.

1.2 Required and supplementary documentation

Lists other documents needed for installation, commissioning, operation, and maintenance.

1.3 Representation of information

Explains how safety instructions, symbols, and abbreviations are used for clarity.

1.3.1 Safety instructions

Details hazard classifications (Danger, Warning, Caution, Notice) and their meanings.

1.3.2 Symbols

Explains symbols used in the documentation that are not safety-relevant but improve clarity.

1.3.3 Abbreviations used

Provides a list of abbreviations used in the document, such as AB, BR, DBV, NG, PE, RE.

Safety instructions

2.1 About this chapter

Emphasizes the importance of safety instructions for preventing injury and damage.

2.2 Intended use

Defines the CytroPac as partly completed machinery for integration into a larger system.

2.3 Improper use

Lists uses considered improper, such as non-compliance with data or unauthorized modifications.

2.4 Qualification of personnel

Specifies the required knowledge and expertise for activities involving the hydraulic power unit.

2.5 General safety instructions

Outlines general safety rules, including accident prevention, environmental protection, and proper product use.

2.6 Product-specific safety instructions

Provides critical safety warnings related to pressurized systems and specific hazards.

2.7 Personal protective equipment

Lists essential personal protective equipment (PPE) required for operation and maintenance.

2.8 Obligations of the machine end-user

Details the responsibilities of the machine end-user for safe operation and personnel training.

General notes on damage to property and damage to the product

Scope of delivery

About this product

5.1 Performance description

Highlights key features like compact design, low noise, cost-effectiveness, and various extension stages.

5.2 Product description

Describes the CytroPac as a frequency-controlled hydraulic power unit with its main components.

5.3 Components overview

Identifies and illustrates the main components of the CytroPac hydraulic power unit.

5.4 Circuit diagram, hydraulic

Presents the hydraulic circuit diagram, labeling key components and connections.

5.5 Identification of the product

Explains how to identify the hydraulic power unit using its nameplate details.

Transport and storage

6.1 Transporting the hydraulic power unit

Provides warnings and instructions for safely transporting the hydraulic power unit.

6.1.1 Preparing for transport

Details necessary preparations before transporting the hydraulic power unit.

6.1.2 Transport using forklifts and similar industrial trucks

Outlines the procedure for safely transporting the unit using forklifts.

6.1.3 Transport using lifting gear

Explains the steps for lifting and transporting the unit using lifting gear and eyebolts.

6.2 Storing the hydraulic power unit

Specifies storage conditions, ideal temperature, and maximum storage time.

Mounting

7.1 Unpacking the hydraulic power unit

Instructions for safely opening the packaging and checking the unit for defects.

7.2 Erecting the hydraulic power unit

Safety warnings and general guidance for positioning and installing the hydraulic power unit.

7.2.1 Dimensions of the hydraulic power unit

Provides detailed dimensions and mounting information for the hydraulic power unit.

7.2.2 Fixation of the hydraulic power unit

Details the process of fixing the unit using an optional mounting plate.

7.3 Connecting the hydraulic supply

Instructions for connecting the hydraulic supply, including warnings and hose requirements.

7.4 Connecting the water supply

Guidance on connecting the cooling water supply to the motor and frequency converter.

7.5 Electrical interface assignment

Overview of electrical connections required for operation and their assignment.

7.5.1 Pinout of the mating connector to connection 12X1: Feed-in/voltage supply

Details the pin assignment for the feed-in/voltage supply connector (12X1).

7.5.2 Mating connector pinout to port 15X1: Enable signal 24 VDC (M12 x 1, customer side)

Explains the pinout for the enable signal connection (15X1).

7.5.4 Mating connector pinout to port 15X1: Enable signal 24 VDC (M12 x 1, customer side)

Details pinout for port 15X1, including configurations for warning/shutdown signals.

7.5.5 Mini USB service interface 14X1 to frequency converter ("Advanced" and "Premium" configuration)

Information on connecting and using the Mini USB interface for configuration.

7.5.6 Multi-Ethernet interfaces

Explains the use of Multi-Ethernet interfaces for "Premium" configuration.

7.5.7 Additional port Safe Torque Off (STO) 22X1 (optional)

Describes the optional STO function for safe motor power interruption.

7.6 Connecting electrical interfaces

General instructions and safety precautions for connecting electrical interfaces.

7.6.1 "Basic" configuration

Details electrical connections for the "Basic" configuration.

7.6.2 "Advanced" configuration

Details electrical connections for the "Advanced" configuration.

7.6.3 "Premium" configuration

Details electrical connections for the "Premium" configuration.

7.6.4 All configurations

Instructions for connecting the Mini USB service interface for all configurations.

Commissioning

8.1 Initial commissioning

Outlines the steps and precautions for the initial commissioning of the unit.

8.1.1 Before commissioning

Checks to perform before commissioning, like line safety and pressure relief valve.

8.1.2 Filling the hydraulic system

Describes the procedure for filling the hydraulic system, including options and fill level indication.

8.1.3 Bleeding the entire hydraulic system of the machine

Refers to machine/system manufacturer instructions for bleeding the system.

8.1.4 Flushing the hydraulic system

Explains flushing to achieve fluid cleanliness and lists required materials.

8.2 Re-commissioning after longer standstill

Steps to follow when putting the unit back into operation after a period of inactivity.

Operation

Maintenance and repair

10.1 Cleaning and care

Guidelines for cleaning the hydraulic power unit, emphasizing proper agents and methods.

10.2 Inspection

Recommendations for documenting inspections to adjust maintenance intervals and detect faults early.

10.3 Warning devices

Explains the LED strip status display for normal operation, warnings, and errors.

10.4 Maintenance schedule

Provides a schedule for visual inspections, checks, and replacements over time.

10.5 Maintenance

General section on maintenance tasks.

10.5.1 Checking the electrical components/installation

Instructions for checking electrical components and installation for damage.

10.5.2 Fill level monitoring

Describes how the fill level sensor monitors for warning and shutdown conditions.

10.5.3 Monitoring of the oil temperature

Explains oil temperature monitoring and possible causes for temperature increase.

10.5.4 Filter element clogging monitoring (return flow filter)

How to monitor filter clogging and when to replace filter elements.

10.5.5 Visual inspection of the filler breather filter

Guidance on performing visual inspections and replacing the filler breather filter.

10.5.6 Pressure value check

Recommends checking pressure values periodically or when drive behavior changes.

10.5.7 Hydraulic fluid care

Advice on hydraulic fluid analysis, sampling, and avoiding recycled fluids.

10.5.8 Visual inspection for leakage, cracking, force effects and corrosion

Instructions for visual inspection of components for common defects like leakage and corrosion.

10.5.9 Checking the heat exchanger

Notes that the heat exchanger requires minimal maintenance and its robustness.

10.6 Spare and wear parts

Refers to a figure and table listing spare and wear parts for the unit.

Decommissioning

11.1 Preparing for decommissioning

Instructions for preparing for decommissioning, including collecting containers.

11.2 Decommissioning process

Steps for safely shutting down and de-energizing the unit.

Demounting and replacement

12.1 Preparing demounting

Steps to prepare for demounting, ensuring stability and draining fluid.

12.2 Demounting

Instructions for demounting, generally in reverse order of mounting.

Disposal

13.1 Environmental protection

Guidance on responsible disposal of the unit, fluid, and packaging.

Extension and modification

Troubleshooting

15.1 How to proceed for troubleshooting

Provides a systematic approach to troubleshooting, emphasizing knowledge of the system.

15.1.1 Overview of the impact of defects

A table detailing common faults, their possible causes, and remedies.

Technical data

Annex

17.1 List of addresses

Provides contact information for Bosch Rexroth service and headquarters.

17.2 Declaration of incorporation

A declaration stating compliance with EC Machinery Directive for partly completed machinery.

17.3 Restricted substances - REACH, RoHS, WEEE

Information on restricted substances and compliance with EU directives.

17.4 Accessories

Lists available accessories, including cables, connectors, and mounting kits.

17.5 Additional document for UL Listing

Provides additional information required for UL certification of the CytroPac.

Alphabetical index