Valvula VT-DFPE PDF

Industrial Hydraulics FAQs
FAQ Title: VT-DFP(E) Identification

Bosch Rexroth Corporation
Hydraulics
Category: Electronics 2315 City Line Road
Bethlehem, PA 18017
Sub-Category: Pump Electronics Tel (847) 645-3600
Question:
Can you indentify VT-DFP (VT-DFPE)?
Answer:
VT-DFP and VT-DFPE are pilot valves for DFE-pumps, like SYDFE1,
SYDFEE, SYDFEN, SYHDFEE. See data sheet RE29016.
If you do not stock a spare pump, at least keep a pilot valve on hand. This is
especially recommended for model codes ending with a dash-number
(like -017). These are Special Order or SO-versions which can increase
delivery time.
After pilot replacement, the pump should be calibrated. See commissioning

instructions, RE30011-B or RE30012-B. For additional assistance, contact
the Service Department.
Attachments:
RE29016
RE30011-B
RE30012-B
Updated: AT_January2013
3/3 proportional directional valves RE 29016/01.12
Replaces: 06.10
1/14
direct operated, with electrical

position feedback as pilot valves
for control systems SY(H)DFE.
Type VT-DFP.
H6633 H6198
Type VT-DFP-.-2X/... with mating Type VT-DFPE-.-2X/... with integrated

connector (separate order) electronics
Component series 2X
Maximum operating pressure 350 bar
Table of contents Features

Contents Page Pilot valve for the pressure and flow control system SY(H)DFE.
Features 1 Actuation by means of a proportional solenoid with electri-
Ordering code 2 cal feedback
Technical data 4 Control electronics:
Electrical connection 6 VT-DFP for SY(H)DFE1 external control
electronics VT 5041-3X
Unit dimensions 11
VT-DFPE for SY(H)DFEE integrated, analog
Project planning information 13
VT-DFPC for SY(H)DFEC integrated, digital with
More information 13
CAN bus interface
VT-DFPn for Sytronix DFEn 5000 (SY(H)DFEn)
Integrated, digital with CAN bus interface, for
variable-speed operation
2/14 Bosch Rexroth AG Hydraulics VT-DFP. RE 29016/01.12
Ordering code
VT-DFP - A - 2X / G24 K0 / 0 / V - *
VT-DFPE - A - 2X / G24 K0 / 0 A 0 C / V - *
VT-DFPC - A - 2X / G24 K0 / 0 A 0 C / V - *
VT-DFPn - A - 2X / G24 K0 / 0 A 0 C / V - *
1 2 3 4 5 6 7 8 9 10 11
Series
Pilot valve for external electronics VT-DFP
Pilot valve with integrated analog electronics VT-DFPE
1
Pilot valve with integrated digital electronics VT-DFPC
Pilot valve with integrated digital electronics, variable-speed VT-DFPn
Spool design
Standard (not for HFC fluids) A
2 2-groove spool (for replacement purposes only) B
4-groove spool (e.g. for HFC fluids) C
3 Component series 2X
4 Direct voltage 24 V G24
5 Connector (without mating connector) 1) K0

Installation orientation plug-in connector (VT-DFP) and/or integrated electronics (also see page 3)
Radially to the pump axis 0
6 Folded 90 in the direction of the subplate with counterclockwise direction of rotation 1
Folded 90 in the direction of the subplate with clockwise direction of rotation 2
Additional functions: Closed-loop control A B C D R

VT-DFP (without)
Selectable pressure controller (high signal) A
Power limitation adjustable at the OBE valve B
VT-DFPE
Power limitation adjustable via analog input C
7
Pressure controller that can be switched off (high signal) D
VT-DFPC Standard A
Teach-In version for cyclic operation A
VT-DFPn
Real-time version (speed calculation without Teach-In) R
Electronics assembly, option
VT-DFP (without)
Standard electronics with leakage oil compensation - - 0
VT-DFPE
8 Standard electronics without leakage oil compensation 1
VT-DFPC Standard 0
VT-DFPn Standard 0
Actual pressure value input Plug-in connector

(description of plug-in connectors on page 6)
VT-DFP (without)
Current input 4...20 mA X1 C
VT-DFPE
9 Voltage input 0...10 V (standard) X1 V
VT-DFPC
Voltage input 1...10 V X1 E
VT-DFPn
Voltage input 0.5..5 V (Standard) 2) X2 F
10 FKM seals suitable for mineral oils (HL, HLP) according to DIN 51524 and HFC fluids 3) V
11 Further details in plain text, e.g. SO variant

= available - = not available Preferred program
RE 29016/01.12 VT-DFP. Hydraulics Bosch Rexroth AG 3/14
Ordering code
Note on feature 6: Installation orientation of the valve electronics

Clockwise direction of rotation, Clockwise direction of rotation, Counterclockwise direction of rotation, Counterclockwise direction of rotation,
installation orientation 0 installation orientation 2 installation orientation 0 installation orientation 1
1) Connector dependent on the valve type (see "Technical data" and "Electrical connection")
2) With the SY(H)DFEn control system with analog interfaces, the plug-in connector X2 cannot be used as actual pressure
value input. Thus, a separate pressure transducer has to be used and connected to plug-in connector X1 in this case.
3) Only in connection with SYHDFE and spool design C (feature 2)
Example of nameplate
1 2 3
1 Material number
MNR: R900703575 SN: 1 FD: 09W26
2 Serial number
3 Date of manufacture
V T- D F P E - A - 2 2 / G 2 4 K 0 / 0 A 0 E / V 4 Production order number

000122242602 5 Type designation
7087
5 4
Made in Germany
Ordering code: Accessories
Version 10/2011, enquire availability
Accessories for VT-DFP Material number Data sheet

Mating connector for solenoid plug R901017011 08006
Mating connector for position transducer of valve R900023126 08006
Compact power supply unit VT-NE32-1X R900080049 29929
Accessories for VT-DFPE, VT-DFPC and VT-DFPn Material number Data sheet
Mating connector 12-pin for central connection X1 without cable (assembly kit) R900884671 08006
Mating connector 12-pin for central connection X1 with cable set 2 x 5 m R900032356
Mating connector 12-pin for central connection X1 with cable set 2 x 20 m R900860399
Test device VT-PDFE-1-1X/V0/0 for SY(H)DFEE and SY(H)DFEC R900757051 29689-B
Compact power supply unit VT-NE32-1X R900080049 29929
Accessories for VT-DFPC and VT-DFPn only Material number Data sheet
Converter USB/serial for laptops without serial interface R901066684
VT-ZKO-USB/S-1-1X/V0/0
Cable for connecting a WIN-PED PC (RS232) to the X2 interface R901156928
Length 3 m
T connector for the simultaneous connection of a WIN-PED PC (RS232) and use R901117164
of the input at plug-in connector X2
Mating connector for interface X3, M12, straight, can be connected independently
R901076910
5-pin, shielded, A-coded, cable diameter 6...8 mm
Technical data (For applications outside these parameters, please consult us!)
general
Type VT-DFP VT-DFPE VT-DFPC VT-DFPn
Storage temperature range C 20 +70 0 +70 0 +70 0 +70
Ambient temperature range C 20 +60 0 +60 0 +50 0 +50
Weight kg 1.96 2.25 2.25 2.25
hydraulic
Hydraulic fluid Mineral oil (HL, HLP) according to DIN 51524; HFC fluids
only in connection with SYHDFE control system and C spool
design C (feature 2 of ordering code)
Hydraulic fluid temperature range C 20 +70
Viscosity range mm2/s 20 380
Maximum admissible degree of contamination of the
Class 18/16/13 (for particle size 4/6/14 m)
hydraulic fluid according to ISO 4406
Operating pressure Port A, P bar 350
Port T bar 100
Technical data (For applications outside these parameters, please consult us!)
electric
Type VT-DFP VT-DFPE VT-DFPC VT-DFPn
External
control elec- Integrated, Integrated, Integrated,
Control
tronics analog digital digital
VT 5041-3X
Operating voltage UB 24 VDC 24 VDC 24 VDC
+40 % 5 % +40 % 5 % +40 % 5 %
Operating range (short-time operation)
Upper limit UB(t)max 35 V
Lower limit UB(t)min 21 V
Current consumption (in static control operation)
Rated current INominal 0.6 A
Maximum current Imax 1.25 A
Actual pressure value input U or I Determination Parameterizable:
X1; pin 10 and 11 by means of 0...20 mA; 4...20 mA; 0...10 V;
See data ordering code 05 V; 0.55 V; 0.1...10 V;
sheet 30242 1...10 V
Inputs Analog current inputs, load RB 100 100 100
Analog voltage inputs RE 50 k 100 k 100 k
Digital inputs Logic 0 0.6 V 8V 8V
Logic 1 21 V 14 V 14 V
ncommand / pactual / UOUT1 1) UA 0 10 V 10 V 10 V
Imax 1.5 mA 2 mA 2 mA
actual / UOUT2 2) UA 10 V 10 V 10 V
Outputs
Imax 1.5 mA 2 mA 2 mA
Digital outputs Logic 0 Ua < 1 V
Logic 1 Ua UB 5 V; 10 mA (short-circuit-proof)
Solenoid coil resistance 2.1 ... 3.2
Coil resistance position transducer at 20 C
Between port 1 and 2 Approx. 113
Between port 3 and 4 Approx. 101
See See See See
Electrical connection
page 6 page 7 page 8 page 9
Protection class according to EN 60529 IP 65 with mounted and locked plug-in connectors
Notice:
For information on the environment simulation testing for the areas of EMC (electro-magnetic compatibility), climate and me-
chanical load, see data sheet 30030-U.
1, 2) With VT-DFPC and VT-DFPn, the outputs are parameterizable, condition as supplied see pages 8/9
Electrical connection: Type VT-DFP... (for external analog electronics)

Details on the electrical connection to the VT 5041-3X amplifier are described in data sheet 30242.
Solenoid
Mating connector 3-pin Z4 M SW according to DIN EN 175301-803
(separate order, see page 4)
53
Connection to Connection to 27,5
connector mating connector 27,5
PE
19
PE 1 2
36
1 2
to the amplifier
M16 x 1,5
30 30
Inductive position transducer

Connection to plug-in connector
Coil connection Connector (view on installation side)
Amplifier
1
Signal
2
4 2 Reference
1 3
4 Feed-in
3 Shield
16 37 Pg7
Mating connector 4-pin Pg7-G4W1F/Pg7 SW
(separate order, see page 4)
15
23
7,8
Electrical connection: VT-DFPE... (with integrated analog electronics)

X1: Central connection
Mating connector according to EN 175201-804 (12-pin), ordering code see section Accessories on page 4
5 4
6 3
10
33
7 11 9 2
8 1
90
Allocation of connector or mating connector and cable set

Signal Allocation in the cable set
Pin Signal Description Type of signal
direction (accessories)
1 +UB Voltage supply IN 24 V DC 1
Supply line
2 0 V = L0 Reference potential for the voltage supply - 2
3 x 1.0 mm
PE Earth Earthing connection for the electronics - Green/Yellow
Signals failures, e.g. cable break command / ac-
3 Fault OUT Logic 24 V White
tual values, controller monitoring (logic 0 = error)
4 M0 Reference potential for analog signals - Yellow
5 command Swivel angle command value IN Analog 10 V Green
6 actual Actual swivel angle value normalized OUT Analog 10 V Violet Supply line
7 pcommand Pressure command value IN Analog 0...10 V Pink 10 x 0.14 mm
shielded (one
8 pactual Actual pressure value normalized OUT Analog 0...10 V 1) Red
end of the
Function depends on electronics type and addi- shield must
9 Brown
tional function, see below be connected
Actual pres- to the control!)
10 IN Analog Black
sure value H Actual pressure value input: Signal level de-
pends on feature 14 of the ordering code
Actual pres- With type "F" (0.5...5 V) reserved
11 - Analog Blue
sure value L
n.c. Gray
Functions at pin 9
Additional Function dependent on feature 7 of the ordering code
Pin Signal direction Type of signal
function (see page 2)
-..A Switching to different oil volume adjustment (switch TD) IN Logic 24 V
-..B Power limitation active OUT Logic 24 V
9
-..C Command value of power limitation IN Analog 0...10 V
-..D Switch off pressure controller IN Logic 24 V
1) When using a pressure transducer with raised zero point (e. g. (4... 20 mA), a voltage of -1...-2.5 V will be output in the event
of a cable break.
X2: Connection of pressure transducer HM 16 (mating connector M12)

Pin Signal HM 16 Pin
3 4
1 OUT, +UB 2 n.c.
3 Reference L0 Top view on mating
connector 5
4 IN, analog, 0.5 to 5 V DC 5 n.c.
2 1
Electrical connection: VT-DFPC... (with integrated digital electronics)

5 4
6 3
10
33
7 11 9 2
8 1
90

Signal Type of Allocation in the cable set
Pin Signal Description
direction signal (accessories)
Supply line
3 x 1.0 mm
Analog input AI2
5 AI2 IN Analog 10V Green
Standard: Swivel angle command value
Analog output Supply line
6 UOUT2 OUT Analog 10V Violet
Standard: Actual swivel angle value normalized
10 x 0.14 mm
Analog input AI1 shielded (one
7 AI1 IN Analog 0...10 V Pink
Standard: Pressure command value end of the
Analog output shield must
8 UOUT1 OUT Analog 10 V Red
Standard: Actual pressure value normalized be connected
9 DI1 Digital input DI1 IN Logic 24 V Brown to the control!)
Actual pres-
10 IN Analog Black
Actual pres- pends on feature 14 of the ordering code
11 - Analog Blue
sure value L
n.c. Gray
X2: Connection of pressure transducer HM 16 and serial interface RS232 (mating connector M12)
Pin Signal HM 16 Pin Signal RS232
3 4
1 OUT, +UB 2 RxD
Top view mating
3 Reference L0 connector 5
4 IN, analog, 0.5 to 5 V DC 5 TxD
2 1
X3: Connection CAN bus and digital input 2 (DI2) (connector M12)
Pin Signal input Pin Signal CAN
34 3
1 n.c. 3 CAN GND
Top view
2 IN, digital IN2 (DI2) 4 CAN-HIGH
connector 5
5 CAN-LOW 12 2
Electrical connection: VT-DFPn... (with integrated digital electronics)

5 4
6 3
10
33
7 11 9 2
8 1
90
Signal Allocation in the cable set
Pin Signal Description Type of signal
direction (accessories)
Supply line
3 x 1.0 mm
Analog input AI2
5 AI2 IN Analog 10 V Green
Standard: Swivel angle command value
Analog output
6 UOUT2 OUT Analog 10V Violet
Standard: Actual swivel angle value normalized
Analog input AI1
7 AI1 IN Analog 0...10 V Pink Supply line
Standard: Pressure command value
10 x 0.14 mm
Analog output shielded (one
8 UOUT1 OUT Analog 10 V Red
Standard: Speed command value end of the
shield must be
Digital input DI1
connected to
Dependent on additional function (feature 7 of the control!)
9 DI1 the ordering code): IN Logic 24 V Brown
Teach-In version: Synchronization bit DI1
Real-time version: Activate real-time operation
Actual pres-
10 IN Analog Black
Actual pres- pends on feature 9 in the ordering code
11 - Analog Blue
sure value L
n.c. Gray
X2: Serial interface RS232 and a switchable digital input S1/pressure transducer input for HM 16
(mating connector M12)
Pin Signal input Pin Signal RS232
3 4
1 OUT, +UB 2 RxD
3 Reference L0
5
4 Analog input 0.5...5 V for HM 16 or 5 TxD
2 1
Digital input 0 V low, 10 V high (max. 12 V)
Dependent on additional function (feature 7 of the ordering code):
Teach-In version: Digital input "Variable-speed operation on, S1" Top view mating
connector
Real-time version: Input as analog input for pressure transdu-
cer HM 16
Electrical connection: VT-DFPn... (continued)

X3: CAN bus and digital input 2 (connector M12)
Pin Signal input Pin Signal CAN
34 3
1 n.c. 3 CAN GND
2 IN, digital IN2 (DI2) 4 CAN-HIGH
Dependent on additional function (feature 7 of the ordering code): 5
12 2
Teach-In version: Start Teach-In, S2
Real-time version: Manual speed provision active, speed is ap-
plied according to the real-time operation status and the setting Top view
of the R parameters. connector
5 CAN-LOW
Unit dimensions (dimensions in mm)

Type VT-DFP...2X/...
3a 4
15
1
35,7
55,5
46,8
32
T A P
85 10 (45)
6
132 80
220
2 5 71 8 34 14
15 34 16 20
7,5 T A P
15
4 2
47
30
45
30
1 3
73
Type VT-DFPE...2X/...
10 9 3b 7 13 12
60
121,5
136,5
126,5
46,8
32
T A P
80 81 (45)
217,5
2 5 8 1 6 0,01/100
71
Rzmax 4
15 34
7,5
Required surface quality of

ABCD the valve contact surface
EF012
6789
34 5
30
45
Item explanation see page 12

Unit dimensions (dimensions in mm)
Type VT-DFPC...2X/... and VT-DFPn...2X/...
10 11 9 3b 7 13 15 12
11 10
100
100
121,5
136,5
46,8
32
T A P
80 81 (45)
217,5
2 5 71 8 1 34
15 34 16 20 14
7,5
ABCD
T A P
EF012
6789
15
34 5
47
45
30
30
73
1 Valve housing 13 Dimension for version VT-DFPE...F, VT-DFPC

2 Proportional solenoid with position transducer and VT-DFPn (connection for HM 16 or CAN bus)
3a Mating connectors for solenoid and position transducer 14 Machined valve mounting face
(separate order see page 4) 15 Space required for CAN connection (plug-in connec-
3b Mating connector for connector X1 (separate order tion on the customer side)
see page 4) Valve mounting screws for all types:
4 Space required for removing the mating connector 4 hexagon socket head cap screws
5 Identical seal rings for ports P, A, and T ISO4762-M6X40-10.9-flZn-240h-L,
Friction coefficient total = 0.09 to 0.14
6 Solenoid rotated by 90 (installation orientation "2") according to VDA 235-101,
7 Connection swivel angle position sensor (rotary angle Tightening torque MA = 7 Nm,
sensor VT-SWA-1-1X) Material number: R913000058
8 Name plate
9 Integrated electronics
10 Mating connector X2 for connecting a pressure trans-
ducer HM 16 (only with VT-DFPE./...F, VT-DFPC...
and VT-DFPn)
11 Mating connector X3 for connecting the CAN bus
(only with VT-DFPC... and VT-DFPn)
12 Space required for plug-in connection (HM 16)
Project planning information
Supplementary notes on the SY(H)DFE control systems can be found in the operating instructions (see section "More informa-
tion about this control system" on this page.).
More information on control systems SY(H)DFE
Operating instructions for SY(H)DFE1 30011-B

Operating instructions for SY(H)DFEE 30012-B
Operating instructions for SY(H)DFEC 30027-B
Operating instructions for SY(H)DFEn 30014-B
Data sheet for SYDFE.-2X 30030
Data sheet for SYDFEn-2X 62240
Data sheet for SYDFE.-3X 30630
Data sheet for SYDFEn-3X 62241
Data sheet for SYHDFE.-1X 30035
Data sheet for SYHDFEn-1X 62242
Data sheet for external control electronics VT 5041-3X for SYDFE1 30242
Data sheet for swivel angle sensor VT-SWA-1-1X 30268
Data sheet for pressure transducer HM 12-1X and HM 13-1X 29933
Data sheet for pressure transducer HM 16-1X 30266
Data sheet for pressure transducer HM 17-1X 30269
Operating instructions for test device VT-PDFE 29689-B
Current information is also available on the Internet under the address http://www.boschrexroth.com/sydfe (English) or
http://www.boschrexroth.de/sydfe (German).
Notes
Bosch Rexroth AG This document, as well as the data, specifications and other informa-
Hydraulics tion set forth in it, are the exclusive property of Bosch Rexroth AG. It
Zum Eisengieer 1 may not be reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany The data specified above only serve to describe the product. No state-
Phone +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain applica-
Fax +49 (0) 93 52 / 18-23 58 tion can be derived from our information. The information given does not
documentation@boschrexroth.de release the user from the obligation of own judgment and verification. It
www.boschrexroth.de must be remembered that our products are subject to a natural process
of wear and aging.
Notes
of wear and aging.
Notes
of wear and aging.
Pressure and flow control system RE 30011-B/05.12
Replaces: 10.10
SYDFE1 series 2X, 3X with external control electronics VT 5041-3X English
Operating instructions
SYDFE1, series 2X SYDFE1, series 3X VT 5041-3X
Valid for the following types:

Pressure/flow control system type
SYDFE1 with external control
electronics VT 5041-3X
The data specified above only serve to describe
the product. No statements concerning a certain
condition or suitability for a certain application can
be derived from our information. The information
given does not release the user from the obligation
of own judgment and verification. It must be
remembered that our products are subject to a
natural process of wear and aging.
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. The delivered product may, therefore, differ
from the product which is pictured.
The original operating instructions were created in

the German language.
RE 30011-B/05.12 | SYDFE1 series 2X, 3X Bosch Rexroth AG 3/96
Contents
Contents
1 About this document.................................................................................5
1.1 Validity of the documentation.......................................................................5
1.2 Required and supplementary documents....................................................5
1.3 Representation of information......................................................................6
2 Safety instructions.....................................................................................9
2.1 About this chapter........................................................................................9
2.2 Intended use................................................................................................9
2.3 Improper use................................................................................................9
2.4 Personnel qualifications.............................................................................10
2.5 General safety instructions.........................................................................10
2.6 Product- and technology-related safety instructions..................................11
2.7 Personal protective equipment...................................................................13
3 General notes on damage to material and the product........................14
4 Delivery contents.....................................................................................15
5 Product description.................................................................................16
5.1 Performance description............................................................................16
5.2 Device description......................................................................................16
5.3 Controller structure and basic operating modes........................................19
5.4 Special operating modes............................................................................21
5.5 Operating pressure limits...........................................................................25
5.6 Ambient conditions.....................................................................................27
5.7 Notes on the selection of hydraulic fluids...................................................27
5.8 Noise level..................................................................................................28
5.9 Shaft variants.............................................................................................29
5.10 Spool variant of the VT-DFPE-x-2X pilot valve..........................................30
5.11 Functions of control electronics VT 5041-3X.............................................30
5.12 Master/slave operation...............................................................................34
5.13 Identification of the product........................................................................38
6 Transport and storage.............................................................................39
6.1 Transporting the SYDFE1 control system..................................................39
6.2 Storing the SYDFE1 control system...........................................................41
7 Installation................................................................................................43
7.1 Unpacking..................................................................................................43
7.2 Installation conditions.................................................................................43
7.3 Installation positions and piping of SYDFE1 systems................................44
7.4 Installing the SYDFE1 control system........................................................47
7.5 Connecting the SYDFE1 control system hydraulically...............................49
7.6 Connecting the SYDFE1 control system electrically..................................52
8 Commissioning........................................................................................59
8.1 Initial commissioning..................................................................................60
8.2 Recommissioning after standstill................................................................72
8.3 Running-in phase.......................................................................................72
9 Operation..................................................................................................73
10 Maintenance and repair...........................................................................74
10.1 Cleaning and care......................................................................................74
10.2 Inspection...................................................................................................74
10.3 Maintenance...............................................................................................75
10.4 Repair.........................................................................................................75
10.5 Spare parts.................................................................................................76
11 Decommissioning....................................................................................78
12 Demounting and replacement.................................................................78
12.1 Required tools............................................................................................78
12.2 Preparing demounting................................................................................78
12.3 Demounting the SYDFE1 control system...................................................78
12.4 Preparing the components for storage or further use................................79
4/96 Bosch Rexroth AG SYDFE1 series 2X, 3X | RE 30011-B/05.12
13 Disposal....................................................................................................79
13.1 Environmental protection...........................................................................79
14 Extension and conversion......................................................................79
15 Troubleshooting.......................................................................................80
15.1 How to proceed for troubleshooting...........................................................84
15.2 Malfunction table........................................................................................85
16 Technical data..........................................................................................89
17 Annex........................................................................................................90
17.1 Address directory.......................................................................................90
17.2 Position of adjustment elements of control electronics VT 5041-3X..........91
17.3 Block circuit diagram of VT 5041-3X .........................................................92
18 Alphabetical index...................................................................................94
About this document
1 About this document
1.1 Validity of the documentation

This documentation is valid for the following products:
SYDF1n series 2X
SYDFE1 series 3X
This documentation is intended for engineers, fitters, operators, service

technicians and plant operators.
These instructions contain important information on the safe and appropriate
installation, transport, commissioning, maintenance, disassembly and simple
troubleshooting of the pressure and flow control systems SYDFE1 series 2X and
3X.
ff Read these instructions completely, especially Chapter 2 Safety instructions
on page 9, before working with the SYDFE1 control system.
1.2 Required and supplementary documents

ff Only commission the product, when you have the documents marked with the
book symbol at hand and have understood and observed them.
Table 1: Required and supplementary documents

Title Document no. Type of document
Order confirmation Contains the pre-set
technical data of your
pressure/flow control
systemSYDFE1
Installation drawing Contains the outer
dimensions, all ports
and the hydraulic
circuit diagram of your
pressure/flow control
system SYDFE1
General operating instructions for RE90300-B Operating instructions
axial piston units
Pressure and flow control system RE 30030 Data sheet
SYDFE1..2X, SYDFEE..2X,
SYDFEC..2X, SYDFEn..2X
Pressure and flow control system RE 30630 Data sheet
SYDFE1, SYDFEE, SYDFEC,
SYDFEn
Axial piston variable displacement RE92711 Data sheet
pump A10VSO series 31, sizes
NG18 to 140
Axial piston variable displacement RE 92714 Data sheet
pump A10VSO series 32, sizes 45
to 180
External control electronics for the RE 30242 Data sheet
SYDFE1 control of the A10VSO
axial piston variable pump,
type VT 5041-3X/...
External control electronics (variant) RD 30242-01 Datenblatt
for the SYDFE1 adjustment of the
axial piston pump A10VSO
About this document
Title Document no. Type of document

3/3 proportional directional valves RD 29016 Datenblatt
direct operated, with electrical
position feedback, as pilot valve for
control systems SY(H)DFE,
type VT-DFP
Axial piston units for use with HF RE 90223 Data sheet
fluids
Hydraulic fluids on a mineral oil RE90220 Data sheet
basis for axial piston units
Pump pre-load valve for control RE 29255 Data sheet
system SYDFE,
type SYDZ 0001-1X
Pressure transducers, RE 29933 Data sheet
types HM 12 and HM 13
Pressure transducer with integrated RE 30266 Data sheet
electronics, type HM 16
Pressure transducer with integrated RE 30269 Data sheet
electronics, type HM 17
Installation, commissioning and RE 07900 Data sheet
maintenance of hydraulic systems
Declaration on environmental RE30030-U Compliance data sheet
compatibility
1.3 Representation of information

In order that this documentation allows you to work directly and safely with your
product, standardized safety notes, symbols, terms and abbreviations are used.
For a better understanding, these are explained in the following sections.
1.3.1 Safety notes

In this documentation, safety instructions precede a sequence of activities
whenever there is a risk of personal injury or damage to equipment. The
precautions described to avoid these hazards must be observed.
Safety instructions are set out as follows:
Signal worD
Type and source of hazard
Consequences in the case of non-observance
ff Measures to avert the hazard
ff <List>
Warning symbol: draws attention to a hazard

Signal word: identifies the degree of hazard
Type and source of hazard: identifies the type or source of the hazard
Consequences: describes the consequences in the case of non-observance
Precautions: states, how the hazard can be avoided
About this document
Table 2: Hazard classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning
Indicates a hazardous situation which, if not avoided,
DANGER will certainly result in death or serious injury.
WARNING could result in death or serious injury.
CAUTION could result in minor or moderate injury.
NOTICE Damage to property: The product or the environment

can be damaged.
1.3.2 Symbols
The following symbols refer to notes, which are not relevant to safety, but
increase the legibility of the documentation.
Table 3: Meaning of symbols
Symbol Meaning
If this information is disregarded, the product cannot be used or
operated in an optimum manner.
ff Single, independent step of action

1. Numbered instruction for action:
The numbers indicate that the activities are to be carried out
2. consecutively.
3.
1.3.3 Terms used

The following terms are used in this documentation:
Table 4: Terms
Designation Meaning
A10VSO Axial piston variable displacement pump, open circuit
HM12 Pressure transducer
HM13 Pressure transducer
IW9 Swivel angle sensor for the SYDFE1 control system
SYDFE1 Pressure/flow control system for external electronics
SYDFE1-2X Pressure/flow control system, series 2X
SYDFE1-3X Pressure/flow control system, series 3X
VT-DFPn Pilot valve with integrated, digital electronics, variable speed
VT-DFP Pilot valve for SYDFE1
VT 5041-3X External control electronics for SYDFE1
About this document
1.3.4 Abbreviations used

The following abbreviations are used in this documentation:
Table 5: Abbreviations
Abbreviation Meaning
A/F Width across flats
EMC Electromagnetic compatibility
GND Ground
NG Nenngre (size)
p Pressure (symbol)
P Power
pact Actual pressure value
pcomm Pressure command value
PCV Precompression Volume
pDiff Control difference between pressure command value and
actual pressure value
PE Protective Earth
PT Pressure Transducer
RE Rexroth document in English language
Switch TD Switching input for volume adjustment
SWA Swivel angle
SWAact Actual swivel angle value
SWAcomm Swivel angle command value
UB Supply voltage
US Unterspannung (undervoltage)
VDE Verband der Elektrotechnik, Elektronik und Informationstechnik
(Association of electrical engineering, electronics and
information technology)
Safety instructions
2 Safety instructions
2.1 About this chapter

The SYDFE1 control system has been manufactured according to the generally
accepted rules of current technology. There is, however, still a risk of personal
injury or damage to equipment if you do not observe this chapter and the safety
instructions contained in this documentation.
ff Read these instructions completely and thoroughly before working with the
SYDFE1 control system.
ff Keep this documentation in a location where it is accessible to all users at all
times.
ff Always pass the product together with the required documentation on to third
parties.
2.2 Intended use

The product is electrical/hydraulic equipment.
You may use the product as follows:
for the electrohydraulic pressure and swivel angle control of an axial piston
variable displacement pump
The SYDFE1 control system is technical equipment, which is not intended for
private use.
Intended use includes that you have read and understood these instructions
completely, especially Chapter 2 Safety instructions.
2.3 Improper use

Any use other than described in the section Intended use is considered as
improper and is therefore not permitted.
If unsuitable products are installed or used in safety-relevant applications,
unintended operational states may occur in the application that can cause
personal injury and/or damage to property. For this reason, use the product only
in safety-relevant applications, if this use is expressly specified and allowed in
this documentation. For example in explosion-protected areas or in safety-related
parts of a control (functional safety).
For damage resulting from improper use, Bosch Rexroth AG will not assume
liability. The responsibility for risks arising from improper use lies exclusively with
the user.
Improper use of the product includes:
if you do not adhere to the technical data, operating conditions and
performance limits given in the data sheet and the order confirmation
if you do not comply with national EMC regulations for the application at hand.
If required, notes on proper installation in line with EMC regulations can be
found in the EMC test documentation from Bosch Rexroth AG (compliance
sheet RE 30030-U). The manufacturer of the system or machine is responsible
for complying with the limit values stipulated in national regulations (European
countries: EC Directive 2004/108/EC (EMC Directive); USA: See National
Electrical Code (NEC), National Electrical Manufacturers Association (NEMA)
as well as regional engineering regulations;
if you use the SYDFE1 control system in a potentially explosive atmosphere.
Safety instructions
2.4 Personnel qualifications

The activities described in this documentation require basic knowledge of
mechanics, electrics and hydraulics as well as knowledge of the associated
technical terms. To ensure a safe use, these activities may therefore only be
carried out by qualified personnel or under the direction and supervision of
qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge and
experience, as well as their understanding of the relevant conditions pertaining to
the work to be done. Qualified personnel must observe the rules relevant to the
subject area.
2.5 General safety instructions

Observe the valid regulations for accident prevention and environmental
protection.
Observe the safety regulations and rules of the country where the product is
used/operated.
Only use Rexroth SYDFE1 control systems in good technical order and
condition.
Observe all notes given on the product.
Persons who install, commission, operate, demount or maintain Rexroth
products must not consume any alcohol, drugs or pharmaceuticals that may
affect their ability to respond.
Only use accessory and spare parts released by the manufacturer in order to
rule out personnel hazards arising from unsuitable spare parts.
Adhere to the technical data and ambient conditions provided in the product
documentation.
If unsuitable products are installed or used in safety-relevant applications,
unintended operational states can occur in these applications, which can cause
personal injury and damage to property. Therefore, use the product only in
safety-relevant applications, if this use is expressly specified and permitted in
the documentation of the product.
You may only commission the product when it has been established that the
final product (for example, a machine or system), in which the Rexroth products
are integrated, comply with national regulations, safety regulations and
standards relevant for the application.
Safety instructions
2.6 Product- and technology-related safety instructions
WARNING
Control system falling down!
SYDFE1 control systems are heavy. In the case of improper handling, they can
fall down and cause severe injuries and crushing, because the parts can be, for
example, sharp-edged, heavy, oily, loose or bulky.
ff Transport the SYDFE1 control system using suitable lifting gear at the point
provided for this purpose.
ff Ensure a stable position while transporting the control system to the place of
installation.
ff Wear personal protective equipment when transporting the control system.
ff Observe national laws and regulations for accident prevention and safety at
work during transport.
Risk of injury caused by systems not shut down!

Working on running systems poses a danger to life and limb. The work steps
described in these operating instructions may only be performed on systems
which were shut down. Before beginning work:
ff Make sure that the drive motor cannot be switched on.
ff Make sure that all power-transmitting components and connections (electric,
pneumatic, hydraulic) are switched off according to the manufacturers
instructions and are secured against being switched on again. If possible,
remove the main fuse of the system.
ff Ensure that the system is completely hydraulically relieved and
depressurized. Please follow the system manufacturers instructions.
ff Only qualified personnel (see Chapter 2.4 Personnel qualifications on
page10) are authorized to install the SYDFE1 control system.
Lines under pressure!

Risk of injury.
ff Never disconnect, open or cut pressurized lines!
ff Before carrying out any installation or other work, depressurize the control
system.
High electrical voltage!

Risk of death and risk of injury from electric shock.
ff Before starting installation work, plugging and unplugging connectors and
carrying out any work, switch the control system off. Secure the electrical
equipment against being switched on.
ff Before switching the control system on, check the protective conductor on all
electrical devices for proper connection according to the wiring diagram.
Safety instructions
WARNING
High noise emission during operation!
The noise emission of SYDFE1 control systems depends, among others, on
speed, operating pressure and the installation situation. Under normal operating
conditions, the noise pressure level may rise above 70dB(A). This can cause
hearing damage.
ff Always wear hearing protection when you work in the vicinity of a running
SYDFE1 control system.
Hot surfaces!
Risk of burning.
The SYDFE1 control systems heats up considerably during operation. The pilot
valve of the SYDFE1 control system gets so hot during operation that you may
burn yourself.
ff Let the SYDFE1 control system cool down before touching it.
ff Protect yourself by wearing heat-resistant protective clothing, e.g. gloves.
Risk of intoxication and injury!

Contact with hydraulic fluids can be damaging to your health (e.g. eye injuries,
skin damage, intoxication upon inhalation and swallowing).
ff Always check the lines for wear and damage before each commissioning.
ff While performing these checks, wear safety gloves, safety goggles and
suitable working clothes.
ff If hydraulic fluid should, nevertheless, come into contact with your eyes or
penetrate your skin, consult a doctor immediately.
ff When handling hydraulic fluids, strictly observe the safety notes of the
hydraulic fluid manufacturer.
Risk of fire!
Hydraulic fluid is easily inflammable.
ff Keep open fire and sources of ignition away from the SYDFE1 control
system.
ff Ensure sufficient ventilation.
CAUTION
Improperly installed lines and cables!
Risk of stumbling!
ff Install cables and lines in a way that nobody can stumble over them.
Uncontrolled system behavior!

The failure of individual components can lead to malfunction of the assembly and
therefore to unforeseeable behavior!
ff Replace or have defective components replaced immediately.
Safety instructions
2.7 Personal protective equipment

Personal protective equipment for users of the product consists of:
Protective gloves and safety shoes for transporting the SYDFE1 control system.
Hearing protection for working in the direct vicinity of the running system.
All components of personal protective equipment must be intact.

General notes on damage to material and the product
3 General notes on damage to material and

the product
NOTICE
Impermissible mechanical loading!
Hitting or impulsive forces on the drive shaft or the pilot valve can damage or
even destroy the SYDFE1 control system.
ff Do not hit the coupling or drive shaft of the axial piston unit.
ff Do not set/place the axial piston unit on the drive shaft or the pilot valve.
ff Never use the SYDFE1 control system as a handle or step. Do not place/lay
any objects on it.
Foreign bodies and contaminants in the control system!

Risk of damage, wear and malfunction due to the ingress of contaminants and
foreign bodies.
ff When installing the control system, observe strictest cleanliness to prevent
foreign bodes such as welding beads or metal cuttings from entering
hydraulic lines.
ff Before commissioning, make sure that all hydraulic connections are tight
and that all seals and closing elements of plug-in connections are correctly
installed and not damaged.
ff Take care that no detergents enter the hydraulic system.
ff Do not use cotton waste or linty cloths for cleaning.
ff Never use hemp as sealant.
Wear!
Wear can cause malfunction.
ff Carry out the prescribed maintenance work at the time intervals specified in
the operating instructions.
Hydraulic fluid is detrimental to the environment!

Hydraulic fluid leakage leads to environmental contamination.
ff Remove any leakage immediately.
ff Dispose of the hydraulic fluid according to the national regulations in your
country.
Insufficient pressure!
If the pressure falls below the specified value, damage can occur or the product
be destroyed.
ff Make sure that the pressure cannot fall under the prescribed minimum value.
Insufficient hydraulic fluid!

If you commission or operate the SYDFE1 control system without or with
insufficient hydraulic fluid, the control system is immediately damaged or even
destroyed.
ff When commissioning or re-commissioning a machine or system, make
certain that the housing chamber as well as the suction and working lines
of the control system are filled with hydraulic fluid and remain filled during
operation.
Delivery contents
4 Delivery contents
1 2 4
3
Fig. 1: Control system SYDFE1-3X
The following is included in the scope of delivery:

1 control system SYDFE1
Before delivery, the following parts are mounted additionally:

1 Transport protection for drive shaft end in the case of keyed shaft
2 Protective cover with mounting screws
3 Plastic plugs/plug screws
4 Protective cover (NG140) or plastic plug on pre-load valve
5 The connection flange is closed operationally safe with a cover (optionally on
variant with through-drive)
Product description
5 Product description
5.1 Performance description

The SYDFE1 control system is designed and built for the electrohydraulic control
of swivel angle, pressure and power (optional) of an axial piston unit. It is intended
for stationary applications.
Please refer to the data sheet and order confirmation for the technical data,
operating conditions and operating limits of the SYDFE1 control system.
5.2 Device description

The SYDFE1 control system is based on an axial piston variable displacement
pump of swashplate design for hydrostatic drives in the open circuit. The flow
is proportional to drive speed and displacement. The flow can be steplessly
changed by adjusting the swashplate.
Open circuit With an open circuit, the hydraulic fluid flows from the tank to the variable
displacement pump and is transported from there to the consumer via a
directional valve. From the consumer, the hydraulic fluid flows via the directional
valve back to the tank.
In the regenerative operating mode (see Chapter 5.4.1 Regenerative operation
on page 22) the hydraulic fluid can also flow from the consumer through the pump
to the tank.
5.2.1 Functional description, section of SYDFE1

The numbers in the description below refer to Fig. 2 and Fig. 3 on page 18.
Pressure and swivel angle control of the SYDFE1 control systems is
accomplished using an electrically controlled proportional valve (2). The
proportional valve determines the position of the swashplate (1) by means of
the actuating piston (4). The displaced flow is proportional to the position of
the swashplate. The counter-piston (3), which is pre-loaded by a spring (5), is
permanently pressurized to pump pressure.
With a non-rotating pump and depressurized actuating system, the swashplate is
held by the spring (5) in position +100 %. With a driven pump and a de-energized
proportional solenoid (8) the system swivels 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 on the actuating piston and the spring force (5) is
achieved at a pressure of 8 to 12 bar. This basic position (= zero stroke operation)
is obtained when the control electronics is inactive (e.g. when the controller
enable has not been granted).
In contrast to this, a pump with external supply swivels to the negative limit
stop (regenerative operation).
The proportional valve is controlled by external control electronics VT 5041-3X,

which is part of the system. This electronics processes all of the control signals
required to operate the SYDFE1 control system.
The external control electronics type VT 5041-3X is designed as plug-in card in
Euro-format. As a standard, it is provided with one command value input each
for pressure and swivel angle (and optional input for power command value). A
pressure transducer senses the actual pressure value. A swivel angle sensor
(7) on the pump senses the actual swivel angle value. The acquired actual
values are processed in the control electronics and compared with the given
command values. A minimum value comparator ensures that automatically only
Product description
the controller assigned to the desired working point is active. In this process,
one system variable (pressure, swivel angle or - optionally - power) is exactly
corrected, the other two system variables are below the given command value.
The output signal of the minimum value generator becomes the command value
for the valve control loop.
The actual value of the valve spool position is sensed using an inductive position
transducer (6). The output value of the valve position controller determines 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 centered position.
When the higher-level controllers demand an increase in the swivel angle
(increase in flow), the valve spool (9) must be moved from the central position
(connection of the actuating piston (4) A T) until the swivel angle reaches the
required value. The movement of the valve spool against the force of the spring
(10) is achieved by a corresponding increase in the electrical current through the
proportional solenoid (8).
A reduction of the swivel angle (reduction in flow) is achieved by connecting the
actuating piston (4) from P A.
Pre-compression volume PCV Since the introduction of A10VSO, series 32, a so-called pre-compression volume
(14) PCV has been available as an optional extra. This variant (feature 32 in the
ordering code for the design of the subplate) is an integral part of the subplate
and cannot be retrofitted.
The PCV reduces pressure pulsation and can contribute to an improvement in the
generation of noise and render secondary measures for the reduction of pulsation
unnecessary. This technology is, however, not employed in the subplate variant
without PCV (feature 22 in the ordering code).
Actuating system supply The actuating system of the pump can be supplied with pilot oil in three different
ways:
1. Internally, without pre-load valve (only possible for operating pressures above
12...20bar, see Chapter 4.5.1 Internal/external pilot oil on page 25)
2. Internally, with pre-load valve (operating pressure 0100 %)
3. External supply via a shuttle valve - automatic changeover between internal/
external via a shuttle valve sandwich plate (see external pilot oil on page 26).
Product description
5 3 7
6
P A T
1 4
2 10 9 8
Fig. 2: Type SYDFE1, series 2X
5 3 14
P A T 6
-100 %
100% Nullhub +100 %
Zero +100%
1 stroke 4
pressure
2 10 9 8
Fig. 3: Type SYDFE1, series 3X

Product description
Basic positions of the swivel angle The sectional drawings overleaf show the mechanical basic position +100 % of
adjustment feature the pump (depressurized, drive at rest). This corresponds to the maximum swivel
angle of the pump.
Zero stroke pressure: Pressure, which the pump with internal supply generates for
its own supply without activation of the pilot valve. The pressure level is usually
within the range of 8 to 12 bar. This pressure level can only be achieved when the
maximum oil flow, which the pump can deliver, is not exceeded. The pump with
internal supply automatically swivels in to zero stroke operation after the electric
drive was started and
when the enable of the control electronics is missing or
in the case of an error message of the control electronics (pre-condition:
VT5041-3X: J1 OFF) or
when the control electronics is de-energized
provided that the required pilot pressure can be built up (consumer line is closed).
In contrast to this, the pump with external supply swivels in to the negative limit
stop -100% under the above conditions!
NOTICE! Cavitation of the pump!
Risk of damage to the pump in the case of systems with external supply.
ff To prevent damage to the pump, provide a pressure relief/anti-cavitation valve
for systems with external supply. If a fault occurs during operation - not during
start-up - the motor must be switched off.
5.3 Controller structure and basic operating modes

Controller structure The controller structure is illustrated in the figure below.
(Pin 24c)
Actual pressure (pin 8c/10c) U
p
Power
Pressure Valve command value
controller
controller
(option)
Power setpoint Minimum Valve
(potentiometer or Pressure setpoint (pin 6c/4c) value controller s
pin 18c/20c) comparator U
Minimum Flow
value controller
comparator
Swivel angle setpoint
s
(pin 14c/16c) U
Actual swivel angle (pin 12c)

SYD_006
Fig. 4: Controller structure
Basic operating modes Up to three controllers are continuously active in the possible operating modes:
Swivel angle controller
Pressure controller
Power controller (optional)
These controllers alternate automatically and jerk-free through evaluation of

minimum value comparators.
During steady-state operation, one of the above controllers is active. For the other
controllers, the actual value is smaller than the command value.
The following operating modes are available:
Product description
5.3.1 Closed-loop swivel angle control

With version VT 5041-3X/1...
VT 5041-3X/2...
ff J4 OFF and
ff connect pin 18a to +24 V.
With version VT 5041-3X/3...

If the axis is to run exclusively in this operating mode, an analog signal within the
range of +10.0 V to UB is assigned to the pressure command value and used to
deactivate the pressure controller (0...+10 V 0...100 % swivel angle).
The pressure transducer signal must be short-circuited or deactivated,
because even actual pressure value signals of 8.0 V have an influence on or
reduce the swivel angle output and hence the valve command value (actuating
speed!).
A precondition for this is, however, that the electronics is set for an actual
pressure value input voltage without raised zero point (e.g. 0 - 10 V, 0 - 20 mA).
Otherwise, electronics set for an actual pressure value branch with raised zero
point would change to an erroneous state when the pressure transducer signal is
missing.
+10 V to UB 6c pcomm
external u
4c Reference potential
u
H 8c pact 0 to +10 V
10c 0 to 5 V u
L
u
14c SWAcomm -10 V to +10 V
16c Reference potential u

u
SYD_008
Fig. 5: Circuitry of control electronics VT 5041-3X for closed-loop swivel angle control
Product description
5.3.2 Closed-loop pressure control
WARNING
Forcefully ejected parts and hydraulic fluid jet!
Risk of severe injury! The electrical pressure control does not assume a
pressure relief function.
ff Make certain that the maximum operating pressure is never exceeded.
ff If a pre-load valve is installed, you can use its pressure relief function. If
no pre-load valve is installed, provide a pressure relief valve, the pressure
setting of which is 10 % (recommended) higher than the operating pressure,
in the pressure line. If you do without this valve, malfunction is possible.
If the axis is to operate in this mode, an analog signal within the range from
+10.0V to UB can be assigned to the swivel angle command value and used
to deactivate the swivel angle controller. However, for some applications,
it is advantageous to limit the permitted swiveling range of the pump by
feedforwarding a suitable swivel angle command value. However, this command
value must be sufficiently great in order that the pressure controller can swivel the
pump out to the required extent.
5.3.3 Power limitation (optional) with VT 5041-3X/3...

This version allows optimum matching with the performance limits of the drive
motor.
Due to the relationship of P comm * pact the power controller intervenes with a
reducing/limiting effect (power hyperbola) via the swivel angle command value
branch, if required.
100
Max. flow [%]
Power
0
0 Actual pressure [%] 100
Fig. 6: Power limitation
5.4 Special operating modes

This chapter describes certain applications. In these cases, the basic operating
modes (see Chapter 5.3 on page 19) are active.
Starting up at zero pressure For starting up SYDFE1 systems, no hydraulic circuit needs to be provided for the
classical start-up at zero pressure.
Product description
When small command values for pressure and swivel angle are provided, starting
up under almost no-load conditions is possible.
Circulation operation (by-pass In the case of systems with internal supply and without pre-load valve, hydraulic
filtration, cooling) circulation circuits must be dimensioned so that a minimum pressure of 8...12 bar
is obtained, because the pump requires this pressure level to be able to respond
to electrical control signals.
Stand-by operation Operating mode of the pump, in which an operating point is steadily closed-loop-
controlled with a corresponding command value over a longer period of time.
Observe the notes on permitted pressures in Chapter 5.5.1 Internal/external pilot
oil (page 25).
Zero stroke operation Operating mode of the pump that refers to the smallest achievable swivel angle
and to which the pump usually changes over when no closed-loop control is
active.
A withdrawal of the enable signal, the non-availability of supply voltage or an error
message (exception: J1 set, see page 63) cause the pump to automatically swivel
in to zero stroke operation (actuating system with internal supply). Whereas
in the case of actuating systems with external supply the pump swivels to the
mechanical positive stop -100% (consumer line closed) irrespective of the
command value received.
The feedforward of 0 bar via the pressure command value branch is not
permitted for actuating systems with external supply. In the case of systems with
internal supply this is problematic only in the case of a step-change from a high
pressure to 0, because undershoots may occur.
5.4.1 Regenerative operation

Regenerative operation is a special operating mode of the SYDFE1 control
system, since in this case the SYDFE1 control system is operated as both,
generator and motor.
Continuous regenerative operation We can distinguish between continuous regenerative operation and brief
regenerative operation. In the first case, by this we understand coupling of the
variable displacement pump with a fixed displacement pump. Here, the two pump
displacements are fed together to a common consumer.
This operating mode can be utilized in conjunction with a fixed displacement
pump in order to increase the displacement. To achieve zero displacement,
the closed-loop controlled pump must take over the entire flow from the fixed
displacement pump and therefore swivels to the negative swivel angle range
(motor operation). It must be noted here that both pump sizes must be matched
to each other so that the controlled pump (in regenerative operation) must swivel
in to max. 70 %. The fixed displacement pump should be mounted to a through-
drive of the SYDFE1 control system.
The following pump variants are available for continuous regenerative operation:
0487: Continuous regenerative operation with external supply
0541: Continuous regenerative operation without external supply (for SYDFE1-3X
only)
In the case of pump variants with external supply this operating mode is
somewhat complicated in terms of engineering and commissioning, because a
pump swiveling in too far (e.g. -75 % instead of -70 %) causes cavitation. We
therefore recommend master/slave operation as an alternative with two
closed-loop controlled SYDFE1 systems or pump variant 0541 for SYDFE1-
3X.
Product description
Continuous operation is possible when the given operating limits are adhered
to. However, at a total displacement of zero (that is, at a negative swivel angle
of the SYDFE1 pump) and at high pressures, the noise level increases and
efficiency deteriorates.
For pumps with external supply, the use of a pressure relief and anti-cavitation
feature as shown in Fig. 7 is indispensable to prevent the pumps running dry.
pmax 0,2 bar
Pressure relief/anti- Q1 Q2 max< 0,7 Q1

cavitation valve required in
the case of external supply
SYD_023
Fig. 7: Circuit diagram for continuous regenerative operation
p[bar]
280
250
Motor operation Pump operation
200
Control system for continuous

regenerative operation:
Operating pressure pHP (bar)
SYDFE1 2X or 3X
150 NG 18...100 with SO 0487 or 0541
NG 140
100
50
Ist [%]
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
0 SYD_014
Fig. 8: Operating limits for series SYDFE1-2X and SYDFE1-3X with special rotary
group for continuous regenerative operation
Brief regenerative operation During brief regenerative operation the variable displacement pump changes over
to motor operation for a limited period of time, e.g. for lowering a load. If the
requirement profile remains within the limits according to Fig. 9, the standard
version of the pump can be used (standard rotary group 0000 or 0479).
Product description
p[bar]
280
250
Motor operation Motor operation

200
Standard rotary group

150
100
50
Ist [%]
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
0 SYD_028
Fig. 9: Operating limits for series SYDFE1-2X and SYDFE1-3X with standard rotary
group for brief regenerative operation
For standard applications, the command value for the swivel angle is provided
within the voltage range of 0+10 V; this command value is interpreted by the
control electronics so that the swivel angle of the pump is controlled within the
swiveling range from 0 % displacement to 100 % displacement.
During regenerative operation, depending on the pump combination, a swivel
angle command value of up to -70 % (or -7 V) has to be provided. If the higher-
level control is not able to generate the command value range of -7 V to +10V,
the normalization of the command value provision can be re-configured using
jumpers J3 and J5.
Table 6: Normalization of swivel angle command value provision

Regenerative Jumper
operation J3 J5
ON ON OFF
OFF OFF ON
Standard: J3 open; J5 set

Swivel angle command value -10...+10 V -100+100 % swivel angle
Regenerative operation: J3: set; J5 open
Swivel angle command value 0...+10 V -100 %+100 % swivel angle or +5 V
corresponds to a swivel angle of 0 %.
Example: A swivel angle of -70 % means zero displacement of the pump

combination. In the regenerative mode, this corresponds to a command value
provision of +1.5 V for the swivel angle.
To vary the displacement for the pump combination from 0 % to 100 %, swivel
angle command values between +1.5 V and +10 V must be provided.
Product description
5.5 Operating pressure limits
WARNING
Excessive pressure!
Risk of severe injury!
ff Make certain that the maximum operating pressure is not exceeded.
Maximum operating pressure At a pressure of 250 bar the following restrictions must be observed for
SYDFE1:
The pressure transducer must be located downstream of a pulsation damper or
the high-pressure hose.
When a standard pilot valve spool is used (version A), the pressure controller
P-gain (see page 70) may have to be reduced. This has an influence on the
accuracy and dynamics of the closed pressure control loop.
The loop gain can also be reduced by installing a pressure transducer of a
higher pressure rating (e.g. 400 bar).
Minimum operating pressure The minimum operating pressure depends on the pilot oil supply and is explained
in more detail in the following chapter.
5.5.1 Internal/external pilot oil

Internal pilot oil supply If the operating pressures of the application are always > 20 bar, the version with
internal pilot oil supply should be selected, because no cavitation due to too small
command values can occur with this version.
Operation is also possible at pressures higher than approximately 12 bar, but
dynamics is restricted within the range below 20 bar.
This minimum (pilot) pressure level ensures that the pump can respond to the
electrical swivel signal at any time. When the consumer line is blocked, the
smallest achievable steady-state swivel angle is the zero stroke angle.
For applications, in which smaller operating pressures occur or are to be
controlled, a pre-load valve (SYDZ for SYDFE1) can be used. In these cases, the
minimum pressure is 1 bar.
Pre-load valve The advantage of the pre-load valve is that the pilot oil pressure of the pump
cannot fall below the value preset on the pre-load valve and that pressures
10bar on the output side can be continuously controlled.
Being equipped with a pre-load valve the pump cannot permanently swivel back
over zero, irrespective of electrical actuating signals or any control errors. This
is not valid for applications, in which, for example, a suspended load can cause
operating pressures 12 bar. In such cases the pump can also be used in motor
operation (for lowering the load). A check valve integrated in the pre-load valve
permits, within certain limits, a reversal of the direction of oil flow.
When using the pump combinations
NG45 with 45/28/18 or

NG28 with 28/18 or
NG18 with 18
in conjunction with the SYDZ pre-load valve on the main pump, there is a
mechanical conflict between port P1 of the pre-load valve and the swivel
angle sensor housing of the built-on rear pump. For this reason, we suggest
that the main pump of the above combinations be equipped with an SAE
flange plate (NG28) or 1 (NG45) having a height of h = 45 mm. The
Product description
construction height of the pump assembly therefore changes by dimension

h.
External pilot oil supply Also here, the minimum pressure is 1 bar. With external pilot oil supply (0479
for external supply or 0487 for external supply plus regenerative operation for
SYDFE1) pressures 10 bar are only permitted briefly (max. 10 minutes).
An additionally built-on sandwich plate with shuttle valve automatically switches
the pilot oil supply between internal or external pilot oil source, with always the
higher pressure level being selected.
A pump for SYDFE1 with external pilot oil supply can be recognized by
the sandwich plate mounted under the pilot valve and
the hose routed around the pump case.
With external pilot oil supply, the actuating system of the SYDFE1 pump works
independently of the actual high-pressure circuit, thus allowing an adjustment also
below an operating pressure of 14 bar within the range of 100 % (change in the
direction of displacement!).
In the following situations, the pump swivels to position -100 % (motor
operation) in an uncontrolled manner:
When the enable of the control electronics is missing or

in the case of an error message (exception: J1 set, see page 63) or
in the de-energized state of the control electronics.
This can lead to cavitation and damage to the pump.
For this reason, special features are to be provided such as a pressure relief and
anti-cavitation valve and actual swivel angle value monitoring.
The pressure relief and anti-cavitation valve diminishes the risk of the pumps
running dry, the effects of which result in a reduction in the pumps service life.
The actual swivel angle value monitor could, for example, switch off the entire
drive or selectively shut off the pilot oil flow.
The following is valid for the actuating pressure:
Pilot oil pressure minimum operating pressure + 30 bar
Recommendation: Absolute pilot oil pressure 20 bar
Further notes on the operation with external supply:
With external supply, the pump does not swivel to zero stroke when the control
electronics is de-energized.
Command values for pressure and flow must always be greater than 1 bar or
5 %, because there is no exact zero pressure or zero swivel angle due to
drift or inaccurate settings. For this reason, selections equal to zero or slightly
greater can lead to cavitation in the worst case.
In order to ensure sufficient lubrication for the pump system at all times, the
actual pressure value must not be less than 10 bar for longer than 10 minutes!!
Notes on dimensioning At a pilot oil pressure of 20 bar the brief pilot oil requirement during swiveling is
ca.17l/min. In practice, this amount of pilot oil is needed only, if the operating
pressure is less than 20 bar during the entire swiveling process and thus the
entire pilot oil demand must be supplied by the external source.
In the steady-state, balanced condition, the pilot oil requirement is less than
1l/min.
Experience has shown that, depending on the operating pressure and swiveling
frequency, the actual pilot oil demand is in the order of 5...15 l/min. In the case
of external supply, a smaller pump size may be selected if an accumulator is
provided.
Product description
5.6 Ambient conditions
5.6.1 Oil-immersed applications

The SYDFE1 control system is suitable for oil-immersed applications.
5.6.2 Ambient temperature

The permissible maximum ambient temperature for SYDFE1 control systems is
70 C at the pump and 50 C at control electronics VT 5041-3X.
We recommend the installation within a ventilated area with moved ambient
air, e.g. in the air flow of an electric motor.
5.7 Notes on the selection of hydraulic fluids

General
The SYDFE1 control system is designed for operation with hydraulic fluids in
accordance with DIN 51 524 (HL/HLP).
Operating viscosity We recommend that the operating viscosity (at operating temperature) be within
the following range, which is optimum in terms of efficiency and service life:
opt = optimum operating viscosity 16... 36 mm/s
This range is referred to the tank temperature in the open circuit.
Viscosity limits The following values are valid for limiting operating conditions:
min = 10 mm/s
Briefly, at max. permissible case drain oil temperature of 90 C
max = 1000 mm/s
Briefly, during cold start
Temperature range The temperature of the hydraulic fluids lies between the following values: (cf.
selection diagram)
tmin = -20 C
tmax = 70 C
Product description
Selection diagram for the hydraulic

fluid 2500-40 -20 0 20 40 60 80 100
1600 1600
1000
600
400
200
V 6
VG
V 32
V 46
V 22
G 8
G
G
G
10
100
0
60
40 36
Viscosity
opt.
20
16
10
5 5
-40 -25 -10 0 10 30 50 70
90
Temperature t in C
tmin = -20 C tmax = +70 C
Hydraulic fluid temperature range
Notes on the selection

In order to be able to select the correct hydraulic fluid, the operating
temperature in the tank (open circuit) in relation to the ambient temperature
must be known.
The hydraulic fluid should be selected so that within the operating temperature
range, the operating viscosity is within the optimal range (opt). This range is
shown as shaded area in the selection diagram.
We recommend that you select the next higher viscosity class.
Example:
At an ambient temperature of X C, the resulting temperature in the tank is
60C. Within the optimum operating viscosity range (opt; grey-shaded area) this
corresponds to viscosity classes VG 46 and VG 68. You should select: VG 68.
The case drain oil temperature, which is subject to the influence of pressure
and pump revving speed, is always higher than the tank temperature.
However, the temperature must not exceed 90 C at any point in the system.
If the conditions described above cannot be complied with due to extreme
operating parameters or high ambient temperatures, please consult us.
Filtration of the hydraulic fluid The finer the filtration of the hydraulic fluid, the better is the achieved cleanliness
class, which, in turn, prolongs the service life of the SYDFE1 control system.
To ensure operational reliability of the SYDFE1 control system, at least
cleanliness class 18/16/13 according to ISO 4406 (for particle sizes 4/6/14 m) is
required.
5.8 Noise level

When compared with, for example, vane pumps, axial piston pumps generate
greater changes in flows and thus pressure pulsations for design-inherent
reasons. Apart from the propagation of air and structure-borne noise, this can
have an influence on fluid-borne noise. In the end, these factors together result in
the general perception of noise.
Noise often induces vibration on other components, which, in turn, also generate
noise. For example, on check valves, which may be installed, the integrated
springs must be adapted to the conditions of the systems, if this is a cause of
excitations leading to the generation of noise.
Product description
The details given for the noise pressure level in the technical documentation refer
to measurements taken in an anechoic room. Influences of the surroundings such
as place of installation, general mechanical concept, piping, etc., are not taken
into account.
5.8.1 Generation of noise in the power unit

Noise is composed of different elements. The total result of noise is influenced
not only by air-borne noise, but also by structure- and fluid-borne noise.
As a result of unfavorable installation and piping conditions, the noise pressure
level of the complete system can be 5 to 10 dB(A) higher than the value of the
pump alone.
Noise can be reduced by taking, for example, the following measures:
Low-noise tank
Damping ring between pump and pump mounting bracket
Flexible pipe conduit
Anti-vibration rails under the motor
Installation of the pump at a sufficient distance to the tank wall
5.8.2 Pulsation damper

For some special applications, we recommend the use of a pulsation damper.
Due to the reduction of typical pump pressure pulsation, this has a positive effect
on the noise level of the hydraulic system as a whole.
Further information can be found in data sheet RE 50142.
5.9 Shaft variants

The SYDFE1 control system is available with keyed or splined shafts. When
compared with the keyed shaft, the splined shaft is not only advantageous with
regard to its degrees of freedom during assembly and operation, but also due to
its increased torque load carrying capacity and its stability under changing loads.
This increased torque load carrying capacity is useful in particular when pump
combinations are to be installed. In the case of multiple pumps, all built-on units
are fitted with splined shafts.
In view of the dynamic load carrying capacity and standardization, we recommend
the use of standard types with splined shafts. This offers advantages with regard
to availability and future spare parts requirements.
When a splined shaft is selected, a clamp coupling must be used for the
mechanical connection to the electric motor. Otherwise, frictional corrosion may
occur that leads to damage to the pump.
Notes on the transmission of permissible maximum torques can be found in the
data sheet.
Product description
Keyed shaft
Due to the advantages of the splined shaft, keyed shafts are not recommended
for new applications. The keyed shaft is no longer used for applications with
through-drive.
If a single pump is to be used later as end pump in a multiple-pump system, a
splined shaft must be selected.
Splined shaft
Splined shaft profiles depend on the size (NG) of the pump. Two different splined
shaft profiles are available in conjunction with SYDFEx :
S-profile for NG18, NG100 and NG140
R-profile for NG28 ... 71
When compared with the S-profile, the R-profile features further improved
properties with regard to the torque carrying capacity of the shaft. This version
represents the optimum for a wide variety of applications.
5.10 Spool variant of the VT-DFPE-x-2X pilot valve

The standard spool according to the ordering code is spool type A (360 spool).
Especially for press applications (280 bar) type C (4-groove spool) has proven in
practice in conjunction with the SYDFE1 control system.
On older systems, a 2-groove spool B was often employed. However, this spool
should no longer be used for new applications due its poor dynamics.
5.11 Functions of control electronics VT 5041-3X
5.11.1 Enable
WARNING
Uncontrolled machine movements!
Risk of severe injury! The enable does not represent a safety function!
ff All further, safety-relevant interventions must be made by the higher-level
control (e.g. switching the drive motor OFF, closing the shut-off valves, .... ).
The enable for the control electronics is granted by applying 24 V to switching

input 26c. This activates the output stage of the VT 5041-3X, i.e. the pilot valve.
The presence of the enable is signaled by LED En. on the front panel.
The following options are provided for connecting enable input 26c:
Controlling by higher-level control (to be preferred)
Fixed wire bridge
Via relay
Conventional switch
The withdrawal of the enable signal at 26c deactivates the valve output stage of
the control electronics and causes the pilot valve to go to a defined position. The
same effect is achieved by switching off the voltage supply.
Product description
This has the following consequences:

With an actuating system with internal supply the pump swivels to the zero
stroke position.
Zero stroke = minimum pressure generated by a pump with internal supply
In contrast to this, a pump with actuating system with external supply
swivels to the mechanical limit stop -100 %.
The enable is always required for normal operation. In the event of a fault, such
a fault can be cleared by withdrawing and re-applying the enable. Clearing of the
fault message is also possible by switching the supply voltage off and then on
again.
5.11.2 Switch TD
Via switching input Switch Td (22c) you can activate a second volume
adjustment.
This function is a new feature when compared with control electronics VT 5041-
2X and is explained in more detail in Chapter 8 Commissioning on page 59.
5.11.3 Pressure controller OFF - master/slave operation

(VT 5041-3X/1... and ...2... only)
This function is provided only for versions without power limitation.
The pressure controller can be deactivated via switching input 18a. This means
that exclusively the swivel angle control of the control electronics is active. The
deactivation of the pressure controller is signaled by LED on the front
panel of the control electronics.
In addition, in conjunction with a set jumper (J4) the command value for the swivel
angle controller is no longer read in from inputs 14c and 16c, but from inputs 18c
and 20c. This function can be utilized for the master/slave operating mode.
When the pressure controller is deactivated, the function of pressure limitation
is no longer effective.
5.11.4 Fault message

The switching output fault message at input 2c signals a trouble-free state with a
24-V level. When a fault is recognized, this is output as collective fault by a signal
level of 0 V at 2c. At the front panel of the control electronics, a fault message is
signaled by LED Err..
Also a missing enable will lead to the issue of a fault message.
Causes for fault messages are described in Chapter 15 Troubleshooting on
page 81.
5.11.5 Signaling of type of control

An active closed-loop pressure control is signaled by the yellow LED with
designation p-control on the front panel.
An active closed-loop swivel angle control is signaled at connection 16a
(switching output +24 V). This information is also shown on the front panel of
the control electronics (yellow LED with symbol: ).
An active power limitation is signaled at connection 18a (switching output
+24V). This information is also provided on the front panel of the control
electronics (yellow LED with lettering Power Limiter). Available only on version
with power limitation!
Product description
Fig. 10: LED indicator lamps
5.11.6 Actual values

The normalized actual pressure value can be picked up at 24c.
The normalization of 0+10 V is made using potentiometers R1 and R2 (front
panel). The signal is related to measuring socket 2.
The normalized actual swivel angle value can be picked up at 12c.
The normalization of -10...+10 V is made using potentiometers R8 and R9 (front
panel). The signal is related to measuring socket 4.
5.11.7 Measuring sockets on the front panel of control electronics

VT5041-3X
The command values for pressure and swivel angle are provided by the higher-
level control and can be measured at measuring sockets 1 and 3.
The actual values for pressure and swivel angle can be measured at measuring
sockets 2 and 4.
The valve command value generated internally by the control electronics as
well as the acquired actual valve value of the pilot valve can be measured at
measuring sockets 5 and 6.
The active swivel angle command value at measuring socket 7 is the command
value that is currently valid for the swivel angle controller. The value can differ
from the swivel angle command value at measuring socket 3 for the following
reasons:
When case drain compensation is active, a compensation value, which is
related to pressure, is added to the command value of measuring socket 3.
When the master/slave function is active, the command value of the swivel
angle is read in at connections 18c(+)/20c(-).
In the regenerative operating mode, the swivel angle command
value of 0+10 V -100 %...-100 % is internally converted into
-10V+10V-100%...-100 % (measuring socket 7).
The power limiter can limit the swivel angle command value. The limiters being
active is signaled by LED Power Limiter on the front panel.
On control electronics with power limitation, measuring socket 8 is used to adjust/

measure the power limit value.
Product description
Table 7: Measuring sockets

Assignment of measuring sockets
Measuring socket 1 Measuring socket 2
Pressure command value Actual pressure value
0...+10 V 0...+10 V
Swivel angle command value Actual swivel angle value
-10 V...+10 V -10 V...+10 V
-100 %...+100 % -100 %...+100 %
Valve command value 10 V Actual valve value 10 V
Measuring socket 7 Measuring socket 81)
Active swivel angle command Power limit 0...+10 V
value 10 V
Reference Reference
1) Only with version with power limitation
5.11.8 Case drain oil compensation

As the operating pressure rises, the amount of internal leakage of the SYDFE1
control system increases. For this reason, a certain external swivel angle
command value is applied in order to exercise a pressure-dependent influence on
the pumps displacement:
The pumps displacement decreases at higher pressures.
The standard versions of the various control electronics therefore comprise
an automatic case drain compensation feature that constantly adds a certain
percentage of the actual pressure value as correction factor to the swivel angle
command value. This, however, results in differences between the externally
provided swivel angle command value and the actual swivel angle signal when
this compensation feature cuts in.
In certain applications and with integrated, connected pressure transducer,
pressure fluctuations, which may occur during displacement operation (swivel
angle control), can have an unfavorable effect on the swivel angle control when
the corrective feature described above is active. In this case, the swivel angle
control can be stabilized by reducing or deactivating case drain oil compensation.
Reasons for pressure fluctuations can be the following:
Process- or material-related
Hydraulic motors with a small number of pistons
Lifting cylinders with a low natural frequency
Overriding closed position or velocity control loop
5.11.9 Power limitation (VT 5041-3X/3... only)

In the case of electronics variants with power limitation, a limiting value can be
set by means of a potentiometer. Alternatively, a limit value can be provided
externally to contacts 18c/20c, if jumper J2 is set in position 2-3.
Product description
100
Max. flow [%]

Power
0
0 Actual pressure value [%] 100
When the power limiter cuts in, the operating variables (pressure and flow) adjust
automatically according to the curve path of the set power hyperbola.
How to adjust the power control is described in Chapter 7 Commissioning on
page 59, the adjustment of the power limitation is described in section 8.1.12 on
page 71.
5.12 Master/slave operation

Circuitry of SYDFE1 for master/slave operation
UB
0V
30a/32a UB 30a/32a UB
28a 0V 28a 0V
SWAact
14c SWAcomm 14c SWAcomm
12c
SWAcomml (I)
16c GND 16c GND
pcomm (I) 6c pcomm 6c pcomm
4c GND 4c GND
8c pact - high 8c pact - high

P
U 10c pact - low 10c pact - low
22a M0 22a M0
Master Slave
Fig. 12: Circuitry of SYDFE1 for master/slave operation without independent

individual operation
Theoretically, an optional number of SYDFE1 control systems can be

hydraulically coupled to achieve greater flows, if necessary.
In this case, it is just required to determine a master pump to which the pressure
transducer, if provided, has to be connected.
Product description
The master then controls both, pressure and swivel angle, in accordance with the
externally provided command values and passes its actual swivel angle value
(SWAact) on to the slave pumps as swivel angle command value (SWAcomm). This
ensures smooth and synchronous swiveling of the pumps.
Consequently, the slave pumps operate only under swivel angle control, which is
the reason why in this operating mode no pressure transducer signal may be fed
to their control electronics.
Circuitry of SYDFE1 with control electronics with power limitation

(VT 5041-3X/3-...)
UB
0V
30a/32a UB 30a/32a UB
Master/slave
28a 0V operation ON 28a 0V
comm (I) 14c SWAcomm 14c SWAcomm
SWAact 12c SWAcomm (II)

16c GND 16c GND
pcomm (I) 6c pcomm pcomm (II) 6c pcomm
10 V... UB
4c GND 4c GND
P 8c pact - high P 8c pact - high

U U
10c pact - low 10c pact - low
22a M0 22a M0
Master Slave
Fig. 13: Circuitry of SYDFE1 for master/slave and independent individual operation
Notes:
Set the pressure transducer input on the slave axis to 0...10 V.

The connection for the position transducer of the pump is not drawn here.
The coupling element (relay, analog switch) can optionally be installed to
control both pumps independently of one another. With the proposal shown
here, both, swivel angle and pressure control, are possible with the slave
pump.
For the master/slave operating mode, the signal pcomm(II) must be set to
maximum (+10 V).
If closed-loop pressure control is to be realized also in the master/slave
operating mode, only the pressure transducer of the master is evaluated
for controlling purposes. If hydraulically separated operation should also be
possible, a separate pressure transducer is required for the slave.
Product description
Circuitry of SYDFE1 with control electronics without power limitation

(VT 5041-3X/1...)
UB
L0
Master/slave operation ON
30a/32a UB 30a/32a UB
28a 0V
28a 0V
18a Master/slave J4: ON
SWAcomm (I) 14c SWAcomm
SWAcomm (II) 14c SWAcomm
SWAact 12c
16c GND 18c SWAact master
16c GND
pcomm (I) 6c pcomm
20c GND
4c GND
pcomm (II) 6c pcomm
8c pact - high 4c GND
P
U 10c pact - low 8c pact - high
P
22a M0 U 10c pact - low
22a M0
Master Slave
Fig. 14: Circuitry of SYDFE1 for master/slave and independent individual operation
Note:
The connection for the position transducer of the pumps is not drawn here.
If closed-loop pressure control is to be realized also in the master/slave
possible, a separate pressure transducer is required for the slave.
Changing over to master/slave operation

Starting point 0 V reference potentials of the PLC/command value source and GND/0 V of the
SYDFE1 electronics must be connected.
Operate both pumps until they reach the point shortly before they change
over to closed-loop pressure control (low, identical pressure level) and are still
hydraulically uncoupled from each other. Approximately identical actual swivel
angle values would be optimal. Set the flow command value to a low value (e.g.
10 %).
When a pre-load valve is used, the pump with the pre-load valve should
preferably be the master pump.
Changing over to master/slave Only in conjunction with VT 5041-3X/3-... (Fig. 13)

operation At low operating pressures, the flow command value, which has been provided by
the control, is withdrawn from the slave pump via a changeover contact suitable
for small signal voltages (or, alternatively, a wear-free analog switch), and the
actual swivel angle value provided by the VT 5041-3X control electronics of the
master pump is connected.
The pressure command value of the slave pump is to be set to 100 % (if required,
using a second changeover contact or by means of software) in order that closed-
loop pressure control of this unit is quasi switched off.
Product description
Only in conjunction with VT 5041-3X/1-... and version VT 5041-3X/2... (Fig. 14)

In the case of control electronics without power limitation: High signal to contact 18a.
For both control electronics:

At the point in time when the master/slave operating mode is activated, the
hydraulic short-circuit valve (connection of the previously separated pressure
circuits) can be activated as well. The activation of this valve may have to be
delayed depending on whether this would improve the system characteristics in
the changeover process.
Deactivating master/slave operation In the master/slave operating mode it is also useful that the control keeps the two
swivel angle command values for the master and the slave pump synchronized in
order that striking differences in the signal level are prevented when the swivel
angle command value source for the slave pump is changed over (from actual
swivel angle value of the master pump back to the control output).
The pressure command value of the slave pump should be set to the same level
as that of the master pump before the slave pump is changed over to individual
operation (jerk-free changeover).
Connection of unused, electrical All analog inputs that are not used, e.g. actual pressure value input in the case of
signal inputs flow control, must be connected to 0 Volt.
In contrast to this, differential inputs of the control electronics that are not used
may also be short-circuited.
5.12.1 Activation sequence of electronics/hydraulics

General Due to various monitoring routines implemented in the electronic assemblies, fault
messages may be generated in the case of an unfavorable order of switching on.
These fault messages cause uncertainty, although they have no real cause of
fault.
In principle, it is valid that all SYDFE1 pump systems that are provided exclusively
with internal pilot oil supply automatically swivel to the operationally safe zero
stroke position in the event of a power failure, missing enable or active fault
message (except, J1 is set, see page 60). However, a precondition for zero
stroke is a minimum pressure of 8...12 bar, which the pump has to build up as
pilot pressure. This can always be ensured, when no oil can flow away from the
pump output (e.g. actuator line hydraulically blocked).
ff Observe the special case of suspended loads!
ff Observe the following activation sequence:
Analog electronics ON: Voltage supply of the electronics
SYDFE1: When switching on the electric motor,
apply enable signal (VT 5041-3X)
and suppress fault messages until
star/delta changeover takes place
Open check valve (if provided)
OFF: Command value provision:
comm = 5 % and p = 10 bar
Close check valve (if provided)
Suppress error message
Withdraw enable with time delay
Switch electric motor off
Switch voltage supply of electronics off
Product description
5.13 Identification of the product

The SYDFE1 control system can be identified by the nameplate. The figure below
shows the example of a SY2DFEC nameplate.
Word mark
Material short text Material number
Date of production
Production job order no. 3FYSPUI ./33'%

4/
4:)%'&&933

Designation of origin Plant

.BEFJO(FSNBOZ
'BCS/S .*/&3"--

%SFI
SJDIUVOH
Fabrication number Direction of rotation
."%&
Production location
Fig. 15: Nameplate
For queries with regard to the pump combination you must indicate the
material number and the fabrication number.
Transport and storage
6 Transport and storage
6.1 Transporting the SYDFE1 control system
SYDFE1 control systems can be transported using a fork lift truck or lifting gear.
ff Make certain that the fork lift truck or lifting device has adequate lifting capacity.
Dimensions and weights Table 8: Dimensions and weights

SYDFE1 2X / size 18 28 45 71 100 140
Weight Pump without through- kg 14 17 23 35 47 62
drive, incl. pilot valve
In addition, pre-load valve kg 3.3 3.3 3.3 6.3 6.3 6.3
In addition, in the case of kg 2 2 2 2 2 2
external actuating system
supply
SYDFE1 3X / size 71 100 140

Weight Pump without through- kg 49 71 75
In addition, pre-load valve kg 6.3 6.3 6.3
In addition, in case of kg 2 2 2
external actuating system
supply
The dimensions vary depending on optional equipment. The figures applicable to your
SYDFE1 control system can be found on the installation drawing or in the data sheet of the
relevant control system.
Carrying the SYDFE1 control SYDFE1 control systems of a low weight can be transported manually, if required
system (the weight for brief lifting should not exceed 15 kg for women and 25 kg for men).
CAUTION! Risk of health damage!
Lifting heavy SYDFE1 control systems involves the risk of health damage!
ff When carrying the SYDFE1 control system, apply suitable techniques for
lifting, lowering and relocating or use suitable lifting gear.
6.1.1 Transporting with lifting gear

Please observe the following points for transporting:
Properties of the load (e.g. weight, center of gravity, mounting and attachment
points).
Way of attaching or suspending the load
Make sure that the load carrying capacity of the lifting gear is sufficient for
transporting the SYDFE1 control system without any risks.
Use textile lifting slings in accordance with DIN EN 1492-2.
For further information on transportation, please contact Bosch Rexroth.
For transporting, the SYDFE1 control system can be connected to a lifting device
using a ring screw or a lifting strap.
Transport with ring screw The drive shaft can be used to transport the SYDFE1 control system as long as
only outward axial forces occur. Consequently, you can suspend the SYDFE1
from the drive shaft.
ff To do this, screw a ring screw completely into the female thread on the drive
shaft. The size of the thread is stated in the installation drawing.
ff Make sure that the ring screw can bear the total weight of the SYDFE1 control
system plus approx. 20 %.
You can lift the SYDFE1 control system without any risk of damage as shown in
Fig.16 using the ring screw screwed into the drive shaft.
Fig. 16: Fixing the ring screw
Transport with lifting strap ff Place the lifting strap around the SYDFE1 control system in such a way that it
neither passes over the attached parts (e.g. valves) nor such that the SYDFE1
control system is hung from attached parts (see Fig.17).
CAUTION! Risk of injury!

During transport with a lifting device, the control system can fall out of the lifting
strap and cause injuries.
ff Hold the control system with your hands to prevent it from falling out of the
lifting strap.
ff Use the widest possible lifting strap.
Fig. 17: Transport with lifting strap

Transport damage must be reported to your contact in the sales organization

within one week. You can find the addresses of our sales locations on the
Internet at: http://www.boschrexroth.com/adressen
6.2 Storing the SYDFE1 control system

Some SYDFE1 control systems are shipped in an anti-corrosion foil (max. storage
time: 12 months). Without anti-corrosion foil, corrosion protection is limited to
transport (a few days). If these control systems are to be stored, then you must
provide preservation like for storage after disassembly (see below).
Requirements The storage rooms must be free from corrosive materials and gases.
The storage rooms must be dry.
The ideal temperature for storage lies between +5 C and +20 C.
Avoid intense light.
Do not stack SYDFE1 control systems and store them shock-proof and slip-
proof.
SYDFE1 control systems can be very heavy (see table 10 Dimensions and
weights on page 39). Also take account of the permissible payloads of your
storage system.
ff Check the SYDFE1 control system monthly for proper storage.
Procedure after expiration of the maximum storage time:

1. Check the entire SYDFE1 control system for damage and corrosion prior to its
installation.
2. Check the SYDFE1 control system for proper function and leaks during a test
run.
3. Replace the shaft seal ring when the storage time of 24 months is exceeded.
After expiration of the maximum storage time, we recommend that you have
the SYDFE1 control system inspected by your responsible Rexroth Service
partner.
Should you have questions regarding spare parts, contact your Rexroth Service
partner responsible for SYDFE1 control systems, see Chapter 10.5 Spare parts
on page 76 for further information.
After disassembly If a demounted SYDFE1 control system is to be stored, it must be preserved

against corrosion for the duration of storage.
The following instructions only refer to SYDFE1 control systems, which are
operated with a mineral-oil based hydraulic fluid. Other hydraulic fluids require
preservation methods that are specifically tailored to them. In such a case,
consult with the Rexroth Service (see Chapter 10.5 Spare parts on page 76
for address).
Rexroth recommends the following proceeding:

1. Clean the SYDFE1 control system, see Chapter 10.1Cleaning and care,
page 74.
2. Drain the SYDFE1 control system completely.
3. For storage times of more than 12 months: Wet the SYDFE1 control system
internally by filling in about 100ml of mineral oil.
For storage times up to 24months: Fill the SYDFE1 control system with anti-
corrosion agent VCI329 (20ml).
Filling via the case drain port.
4. Plug all ports air-tight.
5. Wet non-varnished external metal surfaces of the SYDFE1 control system with
a suitable anti-corrosion agent.
6. Pack the SYDFE1 control system air-tight together with a desiccant in an anti-
corrosion foil.
7. Protect the SYDFE1 control system against impacts during storage. For
further conditions, see Requirements in this chapter.
ff Always observe general laws and regulations when handling water-
endangering and harmful substances.
Installation
7 Installation
Before starting with the installation work, the following documents must be
available:
Hydraulic circuit diagram for the system (available from the system
manufacturer)
Data sheet of the SYDFE1 control system (contains the technical data)
Order confirmation (contains the preset data of the SYDFE1 control system)
7.1 Unpacking
CAUTION
Parts falling out!
If the packaging is not opened correctly, parts may fall out and cause injury.
ff Place the packaging on a flat and solid surface.
ff Only open the packaging from the top.
SYDFE1 control systems are delivered packed in an anti-corrosion foil made of

polyethylene material.
ff Dispose of the packaging according to the national regulations of your country.
7.2 Installation conditions

ff Adhere to all limits specified in the data sheet regarding temperature,
viscosity, cleanliness of the hydraulic fluid.
ff Make certain that the case of the SYDFE1 control system is filled with
hydraulic fluid during commissioning and operation. This is also to be
observed following relatively long standstill periods as the SYDFE1 control
system may empty via the hydraulic lines.
ff To achieve favorable noise values, separate all connecting lines from all
components that can vibrate (e.g. tank) using elastic elements.
ff Make certain that the suction line, case drain line, and return line flow into the
tank below the minimum fluid level in all operational states.
ff Strictly observe extreme cleanliness. The SYDFE1 control system must be
installed without any contamination. Contamination of the hydraulic fluid can
significantly affect the service life of the SYDFE1 control system.
ff Do not use any cotton waste or linty cloths for cleaning.
ff Use suitable liquid detergents to remove lubricants and other difficult-to-
remove contamination. Detergents must not penetrate the hydraulic system.
Installation
7.3 Installation positions and piping of SYDFE1

systems
7.3.1 General
The installation orientation and position of the SYDFE1 control system essentially
determine the procedures during installation and commissioning (such as for
filling the axial piston unit).
Note that you can expect certain installation positions to affect the control
behavior. Because of gravity, dead weight and case pressure, minor characteristic
curve offsets and changes in actuating time may occur.
The installation instructions are tailored to the use of the SYDFE1 control system.
Adhering to these instructions is one of the decisive factors for the service life of
the units.
The instructions refer to standard types and standard installation situations.
Particular installation situations require additional measures to be taken on the
unit, which are documented separately.
Generally, care must be taken that during commissioning and re-commissioning
of a system or equipment, the entire case of the axial piston unit is filled with
hydraulic fluid and remains filled during operation.
NOTICE! Insufficient hydraulic fluid!
Risk of damage or destruction of the rotary group!
ff An optimum filling orientation is assigned to each type. Only this orientation
allows complete filling of the case, which is the reason why this orientation
must be adhered to during commissioning. For re-commissioning, this
orientation should be complied with as far as possible.
In the following, we distinguish between the installation position (pump/motor in

relation to tank) and the installation orientation (position of the pump/motor shaft
end vertical, horizontal, etc.).
Installation position The following installation positions are possible (see Fig. 18):
Pos. a): Pump/motor above the tank (above minimum oil level)
NOTICE! Risk of damage due to loss of hydraulic fluid!

With an installation position above the tank, the case interior may drain through
the case drain line after longer standstill periods (air enters via the shaft seal
ring) or via the service line (gap leakage). The bearings are thus insufficiently
lubricated when the unit is recommissioned.
ff Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission.
Pos. b): Pump/motor next to or below the tank (below minimum oil level), with
the upper edge of the case corresponding to the minimum oil level
Pos. c): Pump in the tank (below minimum oil level).
The pipe routing shown in the figures below represents the routing principle.
Installation
a
+
=
- b
c
SYD_015
Fig. 18: Installation position
Installation orientation The following installation orientations are possible:

Pos.1 horizontal: Shaft end horizontal
Pos.2 vertical: Shaft end upwards
Pos.3 vertical: Shaft end downwards (only possible with pump version 0975)
1 2 3
SYD_016
Fig. 19: Installation orientations
7.3.2 Piping
The installation positions and installation orientations shown in Figs. 18 and 19
determine the routing and installation of
suction lines
case drain lines
bleed lines.
Make sure for all installation positions that always the higher of drain ports L
or L1 is piped. Moreover, the distance between the end of installed pipes and
the minimum oil level must not be shorter than the specified minimum distance
(immersion depth E).
Special points When installing suction and case drain lines, take care that the routing is straight
and short and has as few bends as possible.
When the system is at rest, the lines drain automatically in the course of time due
to the own weight of the hydraulic fluid.
Moreover, the different specific densities of hydraulic fluids must be taken into
account, since fluids with a higher density are more difficult to aspire and also
flow down more quickly. The limit speeds for hydraulic fluids with high density
(mineral oil 0.87 g/ml) are specified in data sheet RE 90223.
Installation
For pumps, a minimum suction pressure is prescribed for port S irrespective of

installation positions and installation orientations:
minimum suction pressure 0.8 bar abs.
To establish the suction pressure (inlet pressure) pabs in dependence on the
displacement or speed, please observe the technical data given in data sheets
RE 30030, 30630 and 30035.
0,8 abs. -0,2
1 0
0 2 -1 1
3 2
Absolute Standard
pressure gauge pressure gauge
SYD_017
Fig. 20: Minimum suction pressure
Case drain piping Dynamic swiveling processes result in increased case pressures that are caused
by the acceleration phase of the case drain oil column. They occur within
milliseconds and must not exceed 6 barabs.. They are influenced by the inductive
resistance of the case drain line (pi = f (diameter, length)). Here, the flow
resistance at the case drain fitting on the pump case plays a subordinate role.
The pi value can only be improved by a larger nominal width of the case
drain line.
General notes Generally, the following must be observed:

ff Each pump should preferably be piped with a separate case drain line.
ff Direct the case drain fluid in the case chamber via the highest case drain port
directly to the tank using a line as short as possible (ca. 1 m). Use a line size,
which matches the port.
ff When the specified line lengths are exceeded we recommend that the nominal
width be increased by one size per additional meter.
ff The nominal width of the case drain line determined by the threaded
connection on the pump case must not be reduced. Use light series pipes
only.
ff Do not use check valves in case drain lines.
ff The case drain line should always enter the tank in the return flow chamber
below the oil level. For tank designs without direct separation of the suction
Installation
chamber, the drain line should be returned to the tank as far away as possible
from the suction port.
ff External influences of pressure, e.g. from manifold tank lines, on the pump
drain port or the pump case are not permitted.
7.4 Installing the SYDFE1 control system
CAUTION
Uncontrolled movements of the control system!
Risk of injury.
ff Make sure that the SYDFE1 control system is safely mounted!
NOTICE
Damage caused by missing seals and plugs!
Fluids and foreign particles can enter and destroy the product.
ff Before installing the SYDFE1 control system, make sure that all seals and
plugs of the connections are tight.
7.4.1 Preparation
1. Check the delivery contents for completeness and transport damage.
2. Compare the material number and designation (ordering code) with the details
on the order confirmation.
If the material number for the SYDFE1 control system is not identical with that
on the order confirmation, contact Rexroth Service for clarification, see
Chapter 10.5 Spare parts on page 76 for address.
3. Before installing the SYDFE1 control system, completely empty it to prevent

mixing with the hydraulic fluid used in the system.
4. Check the direction of rotation of the SYDFE1 control system (on the
nameplate) and make sure that this corresponds to the direction of rotation of
the motor.
The direction of rotation as specified on the nameplate determines the

direction of rotation of the SYDFE1 control system as viewed on the drive
shaft. For information on the direction of rotation of the motor, please refer to
the motor manufacturers operating instructions.
7.4.2 Dimensions of connections

The data sheet contains the dimensions for all connections to the SYDFE1 control
system. Also observe the instructions provided by the manufacturers of the other
components when selecting the required tools.
Installation
7.4.3 General notes

When installing and demounting the SYDFE1 control system, observe the
following general notes and instructions for action:
ff Mount the SYDFE1 control system so that the expected forces and torques
can be transmitted without any risks.
ff The permissible axial and radial loading of the drive shaft, the permissible
torsional vibration, the optimum direction of load forces, as well as the limit
speeds can be found in the data sheet.
7.4.4 Installation with coupling

The SYDFE1 control system is usually flange-mounted to a motor with a coupling.
If you plan to install the unit otherwise, please consult us.
How to install the SYDFE1 control system with a coupling is described in detail in
the following:
1. Mount the relevant coupling half onto the drive shaft of the SYDFE1 control
system according to the instructions of the coupling manufacturer.
The drive shaft end of the SYDFE1 control system is provided with a threaded
bore. Use this threaded bore to pull the coupling element onto the drive shaft.
Refer to the installation drawing for the dimensions of the threaded bore.
2. Make sure that the installation location is clean and free from dirt and foreign
particles.
3. Positively clamp the coupling hub on the drive shaft or ensure permanent
lubrication of the drive shaft. This prevents the formation of frictional corrosion
and associated wear.
4. Transport the SYDFE1 control system to the place of installation.
5. Mount the coupling to the drive in accordance with the instructions of the
coupling manufacturer.
The SYDFE1 control system must not be tightened down before the coupling
has been correctly fixed.
6. Mount the SYDFE1 control system at the place of installation.

7. If necessary, details on the required tools and tightening torques for the
mounting screws are available from the machine or system manufacturer.
For bell housing installation, check the coupling axial play through the
bell window according to the instructions of the machine or system
manufacturer.
For flange-mounting, align the support of the SYDFE1 control system with
the drive.
8. When using flexible couplings, check that the drive is free of resonance after
having completed the installation.
7.4.5 Completing the installation

1. Remove transport screws, if fitted.
2. Remove transport protection.
The axial piston unit of the SYDFE1 control system was delivered with
protective covers and plastic plugs or plug screws. These must be removed
before the system can be connected. Use appropriate tools.
Installation
3. Make certain that the sealing and functional surfaces are not damaged.
CAUTION! Risk of injury caused by ejected plastic plugs!
Operating the SYDFE1 control system with plastic plugs can cause injuries or
damage to the SYDFE1 control system.
ff Before commissioning, remove all plastic plugs and replace them with
suitable, pressure-proof metal plug screws, because plastic plugs are not
pressure-proof.
Setscrews, if provided, are protected against unauthorized resetting by means

of protective caps. Removing protective caps will void the warranty. If you
need to modify the setting, please contact the responsible Rexroth Service (for
address, see Chapter 10.5Spare parts on page 76).
For the variant with through-drive, mount the auxiliary pump in accordance
with the instructions of the pump manufacturer.
7.5 Connecting the SYDFE1 control system

hydraulically
WARNING
Uncontrolled system behavior due to interchanged connections!
Risk of injury! Interchanging the connections will lead to malfunction (e.g. lifting
instead of lowering) and therefore represents a related hazard.
ff When connecting hydraulic components, observe the specified piping
according to the hydraulic circuit diagram of the machine or system
manufacturer.
NOTICE
Hydraulic pipes and hoses installed under stress!
Hydraulic lines, which are installed under mechanical stress, generate additional
forces during operation, which reduces the service life of the SYDFE1 control
system and the machine or system as a whole.
ff Install pipes and hoses stress-free.
Insufficient suction pressure!
Generally, a minimum permissible suction pressure at port S is prescribed
for SYDFE1 control systems in all installation positions. If the pressure at port
S drops below the specified values, damage may occur which can lead to the
destruction of the SYDFE1 control system.
ff Make certain that the necessary suction pressure is achieved.
This is influenced by:
appropriate piping of the suction cross-sections
appropriate pipe diameters
appropriate position of the tank
appropriate viscosity of the hydraulic fluid
The machine or system manufacturer is responsible for dimensioning the lines.

The SYDFE1 control system must be connected to the rest of the hydraulic
system in accordance with the hydraulic circuit diagram of the machine or system
manufacturer.
Installation
Connect exclusively hydraulic lines to the service and function ports.
ff Ensure utmost cleanliness.

ff Install the SYDFE1 control system in a clean condition.
ff Make sure that all ports, hydraulic lines and add-on units (e.g. measuring
devices) are clean.
ff Make sure that no contaminants can enter the system, also while you are
closing the ports.
Notes on the routing of lines Observe the following notes when routing suction, pressure and case drain lines.
ff See to it that the suction line (pipe or hose) is as short and straight as
possible.
ff The line cross-section of the suction line is to be dimensioned so that the
pressure in the suction port does not fall below the minimum permissible value
and the maximum permissible pressure is not exceeded.
ff Observe air tightness of the junctions and pressure resistance of the hose,
also with respect to the atmospheric pressure.
ff In conjunction with the pressure lines, make certain that the pipes, hoses and
connecting elements are approved for the operating pressure range.
ff Always route case drain lines so that the housing is constantly filled with
hydraulic fluid and ensure that no air gets through the shaft seal ring even
during extended standstill periods. The pressure inside the case must not
exceed the limit values specified for the SYDFE1 control system in the data
sheet under any operating conditions. The case drain line in the tank must in
any case end up below the minimum fluid level (see Chapter 7.3Installation
positions and piping of SYDFE1 systems, page 45).
The ports and mounting threads are designed for the operating pressures
specified in the data sheet. The machine or system manufacturer must ensure
that the connecting elements and lines comply with the specified operating
conditions (pressure, flow, hydraulic fluid, temperature) with the necessary
safety factors.
The pressure port of the SYDFE1 control system of size 71 is provided with
threads for two standard flange connection patterns:
SAE 1 (dot-and-dashed line) for pressures above 250 bar and
SAE 1 (dotted line) for pressures up to 250 bar.
Because standard flanges according to SAE 1 are permitted up to 250bar
only, the porting pattern to SAE 1 must be used in the case of operating
pressures higher than 250 bar.
Fig. 21: Flange pattern

Installation
Proceeding To connect the SYDFE1 control system to the hydraulic system:

1. Remove the plug screws from the ports that are to be connected according to
the hydraulic circuit diagram.
2. Use only clean hydraulic lines.
3. Connect the lines according to the hydraulic circuit diagram.
Either pipes or hoses must be connected to all ports according to the
installation drawing and the machine or system circuit diagram or the ports
plugged using suitable plug screws.
The installation drawing contains the dimensions of all connections and ports
on the SYDFE1 control system. Also observe the instructions provided by the
manufacturers of the other hydraulic components when selecting the required
tools.
4. Make sure
that the cap nuts are correctly tightened on the fittings and flanges (observe
tightening torques!). Mark all checked fittings using e.g. a permanent
marker,
that the pipes and hose lines and every combination of connecting pieces,
couplings or connecting points with hoses or pipes have been inspected by
a technically qualified person for their safe working condition.
Tightening torques The tightening torques for the SYDFE1 control system are listed in the following
table:
Threaded hole in the axial piston unit:
The maximum permissible tightening torques MGmax are the maximum values of
the threaded holes and must not be exceeded.
Fittings:
Observe the manufacturers instructions regarding tightening torques for the
fittings used.
Mounting screws:
For mounting screws according to DIN 13/ISO 68, we recommend checking the
tightening torque in each individual case as per VDI 2230.
Plug screws:
For the metal plug screws that come with the SYDFE1 control system, the
required tightening torques of plug screws MV apply.
Risk of mix-ups with threaded SYDFE1 control systems are used in applications with metric as well as with
connections imperial system of units.
Both, the system of units as well as the size of threaded hole and threaded plug
(e.g. plug screw) must match.
Since the systems cannot be distinguished visually, there is a risk of mixing up.
WarnIng! Wrong threaded plug!
Risk of serious injury, if a threaded plug is used that differs from the threaded
hole in terms of unit system and size and is pressurized. The threaded plug may
loosen itself or even be ejected from the hole in a projectile-like manner.
Hydraulic fluid can be discharged from this leakage point.
ff Use the drawings (installation drawing/data sheet) to determine the required
threaded plug for each fitting.
ff Make certain that there are no mix-ups when assembling valves, mounting
screws and plug screws.
ff For all threaded holes, use a threaded plug from the same system of units and
of the correct size.
Installation
Table 9: Tightening torques of threaded holes and plug screws
Max. permissible tightening Required tightening torques for

Thread size of ports A/F hexagon socket
torque of threaded holes MGmax plug screws MV
M10x1 DIN 3852 30 Nm 12 Nm 5 mm

M12x1.5 DIN 3852 50 Nm 25 Nm 6 mm
M14x1.5 DIN 3852 80 Nm 35 Nm 6 mm
M16x1.5 DIN 3852 100 Nm 50 Nm 8 mm
M18x1.5 DIN 3852 140 Nm 60 Nm 8 mm
M22x1.5 DIN 3852 210 Nm 80 Nm 10 mm
M26x1.5 DIN 3852 230 Nm 120 Nm 12 mm
M27x2 DIN 3852 330 Nm 135 Nm 12 mm
M33x2 DIN 3852 540 Nm 225 Nm 17 mm
M42x2 DIN 3852 720 Nm 360 Nm 22 mm
5/16-24 UNF-2B ISO 11926 10 Nm 7 Nm 1/8 in
3/8-24 UNF-2B ISO 11926 20 Nm 7 Nm 5/32 in
7/16-20 UNF-2B ISO 11926 40 Nm 15 Nm 3/16 in
9/16-18 UNF-2B ISO 11926 80 Nm 25 Nm 1/4 in
3/4-16 UNF-2B ISO 11926 160 Nm 62 Nm 5/16 in
7/8-14 UNF-2B ISO 11926 240 Nm 127 Nm 3/8 in
1 1/16-12 UN-2B ISO 11926 360 Nm 147 Nm 9/16 in
1 5/16-12 UN-2B ISO 11926 540 Nm 198 Nm 5/8 in
1 5/8-12 UN-2B ISO 11926 960 Nm 320 Nm 3/4 in
1 7/8-12 UN-2B ISO 11926 1200 Nm 390 Nm 3/4 in
For the tightening torques for spare parts, please refer to the data sheet.
7.6 Connecting the SYDFE1 control system electrically

The machine or system manufacturer is responsible for the layout of the electrical
control.
With electrically controlled SYDFE1 control systems, the electrical control
must be connected according to the circuit diagram of the machine or system
manufacturer.
The VT 5041-3X control electronics is connected using a 32-pin female multipoint
connector and can be installed in a Euro rack or in a card holder from Rexroth
(VT3002 according to RE29928).
CAUTION! Live installation!
Risk of injury when plugging or unplugging connectors under voltage.
ff Before carrying out any installation work or plugging or unplugging connectors
from the product, disconnect the SYDFE1 control system from the power
supply or the voltage source or de-energize it reliably. Damage to the control
system caused by incorrect installation is not covered by the warranty!
1. Disconnect the relevant system part from the power supply.

2. Connect the SYDFE1 control system electrically (24 V).
Installation
7.6.1 Cabling of electronic components

Generally, the following is valid:
Use low-capacitance cables according to the safety regulations of the

German VDE or national electrical safety regulations of your country.
Whenever possible, establish the cable connections without intermediate
terminals!
Only select cables that have the actually required number of wires (avoid
superfluous wires).
The installation of electromagnetic sources of interference, e.g. unearthed
contactors, in the direct vicinity of the pilot valve is not permitted.
Installing power cables in the vicinity of the control electronics is not
permitted.
Do not install cables in the vicinity of power cables.
No switches or relay contacts may be installed in the electrical connections
between the pump/proportional valve and control electronics, because
breaking of a connection results in fault messages or malfunctions. Whenever
possible, do without intermediate terminal points or reduce their number to a
minimum.
Cables of inductive position transducers, swivel angle sensors and of the
pressure transducer must be shielded. Connect the shield only on one side
to the control electronics, see Fig. 22. Never connect the shield to the valve,
pump or pressure transducer.
Transducer
The shield is not connected to the The shield is brought out and
plug-in connector to the transducer connected to 26a
Fig. 22: Connection of the cable shield
Because it is practically almost impossible to connect all shields directly to 26a,

the shields of all relevant cables should be brought into contact with a busbar and
then the busbar connected to 26a. When selecting this connection variant, see to
it that the connected surfaces of the shields are as large as possible.
7.6.2 Voltage supply of control electronics VT 5041-3X

Control electronics VT 5041-3X must be supplied with 24 V DC voltage. If this
voltage supply cannot be provided by the machine, use a power supply unit
VT19085 (NE32) according to data sheet RE 29929. In this case, the +24 V of
the power supply unit is to be connected to contact 30a of the female connector,
and 0 V to contact 28a (recommended cross-section of the supply cable min.
1.5mm).
Recommendation:
The voltage supply for control electronics VT 5041-3X should be protected on the
machine side with a 1.6 A/slow-blowing fuse.
Installation
7.6.3 Selection, place of installation and mounting orientation of

the pressure transducer
Selection of the pressure To reduce the number of variants, only pressure rating 315 bar is given in the
transducers ordering code of the SYDFE1 control systems. If required, other pressure ratings
can be combined (with the correct selection of the suitable electrical interface!).
Such pressure transducers for the SYDFE1 control system must, however, be
ordered separately.
In terms of signals, the sensors have to be distinguished as follows:
Sensors with current interface
Sensors with voltage interface.
Here, the usual signal limits are between 0...20 mA or 0...10 V, respectively.
Within these limits, further modifications are available that depend on whether, for
example, monitoring for cable break is to be implemented.
From a technical point of view, the efficiency of the pressure transducer must
be adapted to the SYDFE1 system in order that the best possible results can be
obtained with regard to accuracy, dynamics and repeatability.
The pressure transducers recommended by us are listed in the RE data sheets of
the relevant SYDFE1 system.
Our pressure transducer model HM17 is available with various current and
voltage interfaces. The variants with current interface, HM17...C..., are to be
connected like the HM12. Variants with voltage interface, HM17...H..., are to
be connected like the HM13. Accordingly, the engineering notes on HM12/
HM13 are valid (see below).
Our pressure transducer model HM12 with current interface (4...20 mA) is
provided with a 2-conductor connection and allows the fail-safe transmission of
signals even over greater distances.
Further pick-offs can be looped in taking into account the relevant input
resistances.
Our pressure transducer model HM13 with voltage interface (0...10 V) has a
3-conductor connection and an integrated DC/DC converter, which effectively
rules out disturbances on the analog signal caused by the voltage supply.
CAUTION! Uncontrolled increase in pressure!

Risk of injury!
ff The pressure transducer must be wired so that it cannot be short-circuited,
because in the event of a missing pressure signal, the control electronics
can no longer detect the pressure, which causes an uncontrolled increase in
pressure.
Place of installation of the pressure Favorable places of installation of pressure transducers turned out to be not in the
transducer direct vicinity of the pump, but, for example, downstream of the (flexible) pressure
hose:
Always between pump and check valve (if fitted)
Do not use minimess lines
Mounting orientation of the We recommend suspended mounting of the pressure transducer so that bleeding
pressure transducer problems (and hence control oscillations) can be ruled out right from the start.
If, due to the installation orientation of the pump, a pressure transducer must
be installed vertically directly in the pump or in the pre-load valve, we
recommend another place of installation for the pressure transducer.
Installation
HM12 Pressure transducers of type HM12 are provided with a 2-wire current interface
and can be connected to control electronics VT 5041-3X as shown below.
The voltage supply for the pressure transducer must be provided in accordance
with the data sheet.
For more details about the pressure transducers HM12 and HM13, see data sheet
RE29933.
We recommend the use of the following cable type: LiYCY 2 x 0.25 mm
Fig. 23: Connection pattern for pressure transducer HM12
HM13 Pressure transducers of type HM13 are provided with a voltage output of
0...+10V as actual pressure value signal and can be connected to control
electronics VT 5041-3X as shown on the figure below.
with the data sheet.
For more details about the pressure transducers HM12 and HM13, see
RE29933.
Fig. 24: Connection pattern for pressure transducer HM13

Installation
7.6.4 Connecting the valve position transducer

Basically, the pinout of the VT 5041-3X has remained unchanged when compared
with version VT 5041-2X, i.e. control electronics VT 5041-3X can sense the
position transducer signal according to the specification of the VT 5041-2X
without requiring a different sensor cable.
Care must be taken that jumper J8 is set on control electronics VT 5041-3X..
Fig. 25: Connection of the valve position transducer
The following is valid for all new systems:

In the case of cable lengths up to 50 m the connection can be established using a
standard cable. Make certain that jumper J8 is set on control electronics VT5041-
3X .
Recommended cable type: LiYCY 5 x 0.25 mm
Jumper
J8 ON
Valve position
transducer
Shield Shielding effect
Cable type:
gr = gray
E.g. LiYCY 5 x 0.25 ws = white
bn = brown
Caution: The order of wire gb = yellow
assignment is essential! gn = green
Fig. 26: Cabling for cable lengths up to 50 m
If distances of 50 m or greater must be covered, we recommend that twisted pair

cables be installed. In this case, jumper J8 must not be set on control electronics
VT 5041-3X.
Recommended cable type: LiYCY(TP) 2 x 2 x 0.25 mm
Installation
Valve position
transducer
Shield
Fig. 27: Cabling for cabling lengths of more than 50 m
7.6.5 Connecting the swivel angle sensor

Recommended cable type: LiYCY 3 x 0.25 mm:
If control electronics VT 5041-3X is used in a system as substitute for control
electronics VT 5041-2X, it must in any case be checked in advance that no
connection is established between pin 12a and 26a. Moreover, connection
12a of control electronics VT 5041 must not be connected to a further
connection!
Swivel angle
sensor
R8: Zero point

R9: Adjustment
To swivel angle
controller 10 V corresponds to 100 %
SWAact
Fig. 28: Connection for swivel angle sensor
Fig. 29: Connection for clockwise rotating pump

Installation
Fig. 30: Connection for counter-clockwise rotating pump
7.6.6 Connecting the solenoid of the proportional valve

Install the solenoid cable separately from other cables, in particular the cables
of inductive position transducers. It is recommended that the solenoid cable be
shielded.
We recommend the use of the following cable type: LiYCY 1.5 mm for up to 50m
length; in the case of longer cable routes, use a greater cable cross-section!
Fig. 31: Connection of the proportional valve solenoid
Attention: Connect shield to PE or ground; not to 26a!!
7.6.7 Command values for pressure, swivel angle and power limit
General notes:
The command values for pressure and swivel angle are provided as analog
variables within the voltage range of 0+10 V; this corresponds to 0+100 %
of the physical range of values.
Command values may only be passed on using appropriate contacts that are
suitable for currents <1 mA.
The use of shielded cables is recommended (connect shield of the signal cable
to 26a).
Command value for power limit

The value for power limitation can either be provided internally by means of
potentiometer R3 or externally with a voltage level of 0...10 V.
If the power limit value is to be provided externally, jumper J2 must always be
set in position 2-3 and potentiometer R3 (front side) must be turned to the left-
hand positive stop.
If the external input is not used, connections 20c and 18c must always be
connected to 22a (M0).
Commissioning
8 Commissioning
WARNING
Working in the danger zone of a machine or system!
Risk of severe injury due to unsafe working.
ff The machine or system may only be commissioned when safe working is
ensured.
ff Pay attention to and eliminate potential danger sources before
commissioning the machine or system.
ff Nobody may stay in the danger zone of the machine or system.
ff The emergency stop button for the machine or system must be within the
operators reach.
ff Always strictly observe the instructions of the machine or system
manufacturer during commissioning.
Uncontrolled system behavior!

Electrical and hydraulic connections and ports, which are not connected, can
cause malfunction and fluid to be ejected, which can injure you.
ff Commission only a completely installed product.
NOTICE
Non-compliance with the protection class due to missing seals and plugs!
Fluids and contaminants may penetrate and damage the product.
ff Prior to commissioning, make sure that all seals and plug-in connections are
tight.
Ingress of contaminants!
Damage to the SYDFE1 control system! Contamination of the hydraulic fluid
causes wear and malfunction. In particular foreign bodes such as welding beads
and metal chips in the hydraulic lines can damage the SYDFE1 control system.
ff Observe utmost cleanliness during commissioning.
ff Make sure that no contaminants can enter the system when you close the
measuring ports.
Insufficient hydraulic fluid!

Insufficient amounts of hydraulic fluid can destroy the product.
ff Make sure that the case of the SYDFE1 control system is filled with hydraulic
fluid during commissioning and during operation. This must also be observed
during longer periods of standstill, because the SYDFE1 control system can
drain through the hydraulic lines.
Commissioning
8.1 Initial commissioning
NOTICE
Air pockets in the bearings!
The device can be destroyed.
ff Make certain that with the drive shaft upwards installation position the pump
case is completely filled with hydraulic fluid during commissioning and during
operation.
ff Check the hydraulic fluid level in the pump case at regular intervals. If
required, carry out recommission. For above-tank installation, the case
chamber can run dry through the case drain line (ingress of air via the
shaft seal ring) or via the working line (gap losses). Consequently, the
bearings are no longer sufficiently lubricated when the control system is
recommissioned.
ff Ensure that the suction line is always filled with hydraulic fluid during
commissioning and operation.
ff Let the product acclimate itself for several hours before commissioning,
otherwise water may condense in the housing.
When carrying out any work in conjunction with commissioning the SYDFE1
control system, observe the basic safety instructions and intended use
provided in Chapter 2 Safety instructions on page 9.
8.1.1 Filling the SYDFE1 control system
NOTICE
Spilled hydraulic fluid!
Discharging or spilling hydraulic fluid while filling the SYDFE1 control system can
lead to environmental pollution and contamination of the groundwater.
ff When filling and changing the hydraulic fluid, always place a catch pan under
the SYDFE1 control system.
ff Observe the information in the safety data sheet for the hydraulic fluid and
the specifications provided by the system manufacturer.
You will require an approved hydraulic fluid:

The machine or system manufacturer can provide you with precise data of the
hydraulic fluid. Details on minimum requirements for mineral-oil-based hydraulic
fluids are available in the Rexroth publication RE90220.
To ensure functional reliability of the SYDFE1 control system, the hydraulic fluid
must comply at least with cleanliness class 18/16/13 according to ISO 4406 for
particle sizes 4/6/14 m. For permissible temperatures, see Chapter 4.7 Notes
on the selection of hydraulic fluids from page 27 onwards.
The SYDFE1 control system should be filled using a filling and filtration unit
(10mfiltration rating). The control system must not be powered when being
filled.
Commissioning
1. Fill and air-bleed the SYDFE1 control system via the appropriate ports, see
Chapter 7.3 Installation positions and piping of SYDFE1 systems on page
44. The hydraulic lines of the system must also be filled.
2. Test the direction of rotation of the drive motor. To do this, rotate the motor
briefly at the lowest rotational speed (inching). Make sure that the direction of
rotation of the axial piston unit corresponds to the indication on the nameplate,
see also Chapter 5.13 Product identification, Fig.15:Nameplate on page
38.
3. Operate the SYDFE1 control system at low speed (inching mode) until the
pump system is completely filled and bled. For checking purposes, drain the
hydraulic fluid at the case drain port and wait until fluid flows out without any
bubbles.
4. Make certain that all ports are either connected to pipes or plugged according
to the general circuit diagram.
8.1.2 Testing the hydraulic fluid supply

The SYDFE1 control system must always be supplied with sufficient hydraulic
fluid. it is therefore indispensable to ensure the supply with hydraulic fluid at the at
the start of the commissioning process.
When you test the hydraulic fluid supply, constantly monitor the noise generation
and check the hydraulic fluid level in the tank. If the SYDFE1 control system
becomes louder (cavitation) or the case drain fluid flows out with bubbles, this
is an indication that the SYDFE1 control system is not sufficiently supplied with
hydraulic fluid.
Notes on troubleshooting can be found in Chapter 15 Troubleshooting on page
81.
To test the hydraulic fluid supply:
1. Allow the drive motor to run at slowest speed. The SYDFE1 control system
must be operated under no-load conditions. Pay attention to leakage and
noise.
2. Check the SYDFE1 control systems case drain line while testingt. The case
drain fluid should not contain any bubbles.
3. Check the suction pressure at port S of the SYDFE1 control system pump.
For the permissible value, please refer to data sheet RE 92050.
4. Check the case drain pressure at connected port K1 or K2. For the
permissible value, refer to data sheets RE30030 and RE 30630, respectively.
8.1.3 Performing a flushing cycle

To remove foreign particles from the system, perform a flushing run for the entire
system.
Flushing is to be carried out with a separate flushing unit. Observe the
instructions of the flushing unit manufacturer for the detailed procedure for
carrying out the flushing cycle.
Commissioning
8.1.4 Configuring switches and jumpers of the VT 5041-3X

Before commissioning you have to configure the switches and jumpers of control
electronics VT 5041-3X for the application at hand. A layout that shows the
position of setting elements can be found in Chapter 17.2 on page 91.
Signal adjustment of the The signal range of the connected pressure transducer must be matched with the
actual pressure value (S2) signal adjustment of the VT 5041-3X. To this end, switch S2 must be configured.
The table below shows the factory setting for a transducer with the level
0+10V.
Table 10: Signal adjustment of the actual pressure value

Signal adjustment Switch S2
of actual pressure
.1 .2 .3 .4 .5 .6 .7 .8
value
V 0 - 10 V OFF OFF OFF OFF OFF OFF ON ON
E 0 - 10 V OFF OFF OFF OFF ON OFF OFF ON
D 0 -5V OFF OFF ON ON OFF OFF ON ON
F 0.5 - 0 V OFF OFF ON ON ON OFF OFF ON
B 0 - 20 mA ON ON OFF OFF OFF OFF ON ON
C 4 - 20 mA ON ON OFF OFF ON ON OFF OFF
V = factory setting
Case drain compensation (J6, J7) Case drain compensation is used for compensating for leakage of the pump and
can be set to the following values by means of jumpers J6 and J7 on control
electronics VT 5041-3X.
Table 11: Adjustment of case drain compensation

Case drain Jumper
compensation
J6 J7
OFF OFF OFF
4% OFF ON
6% ON OFF
10 % ON ON
Factory setting: Case drain compensation OFF.
The swivel angle is increased in dependence upon the normalized actual

pressure value. Example: With a case drain compensation of 10 % and an actual
pressure value setting of 315 bar, the swivel angle increases by 8.9% at 280 bar.
The simultaneous use of power limitation and case drain compensation can
lead to vibrations.
At a pressure of 280 bar, pumps of control system SYDFE1 show a leakage rate
of about 8 %. On this basis, the following settings are recommended:
Table 12: Settings of actual pressure value normalization

Normalization of actual pressure value Setting of J6/J7
200 bar 4%
ca. 250 bar 6%
315 bar 10 %
Commissioning
Valve command value monitoring Control electronics VT 5041-3X includes a monitoring function that evaluates the
(J9) control error. Usually, the system reduces the control deviation to almost zero
within a few 100 msec. In the event of a fault, the correction takes, however,
longer in most of the cases.
The monitoring feature continuously checks the valve command value (= control
deviation x controller gain; measuring socket 5) and signals an error as soon as
the amount exceeds the value of 4 V for longer than 1 second.
To be still compatible with control electronics of series 2X in terms of function, this
monitoring feature can be deactivated by means of a jumper (J9).
Table 13: Activation/deactivation of valve command value monitoring

Valve command value monitoring Jumper J9
ON ON
OFF OFF
Factory setting: Valve command value monitoring deactivated: J9 = OFF
Depending on the command and actual values, the monitoring feature may cut
in while the drive motor is switched off. This can take place, if the command
values for pressure and/or swivel angle are not matched to the current actual
values for pressure and swivel angle and the consequence is a valve
command value of > 4 V (amount!). The valve command value can be
measured at measuring socket 5 of the control electronics.
Valve shutdown in the event of a The safety concept of control electronics V T5041-2X is designed so that the
fault (J1) detection of a fault is signaled by the fault signal outputs and, at the same time,
the activation of the pilot valve is interrupted. This ensures that the pilot valve
takes a defined position and the pump with internal pilot supply swivels to the
zero stroke position.
With control electronics VT 5041-3, the shutdown of the valve output stage can be
prevented by means of a jumper. To this end, jumper J1 must be set.
Table 14: Activation/deactivation of valve shutdown

Valve shutdown in the event of a fault Jumper J1
Active OFF
Inactive ON
Factory setting: Valve shutdown active; J1 not set
Attention:
When the fault-triggered shutdown of the valve output stage is deactivated,
the higher-level control must take appropriate measures (withdrawal of enable
for VT 5041-3X, pump motor OFF...) in the case of faults to ensure safety for
man and machine.
Function of pressure controller OFF This function is available only on the variant without power limitation
or master/slave (J4) (VT 5041-3X/1... and VT 5041-3X/2...)!
Pressure controller OFF

On the VT 5041-3X variant without power limitation, connection 18a is provided
as switching input.
By applying +24 V to this input, the pressure controller of the control electronics
can be switched off. In this way, the function of the DFE control is reduced to that
of an FE control. To this end, it is not required to connect the pressure command
value and the actual pressure value to the control electronics.
This function can also be used by the higher-level control to deliberately
deactivate the pressure controller of the VT 5041-3X for certain time intervals
within a machine cycle.
Commissioning
Master/slave function
When the switching input is connected to 18a and the pressure controller is
deactivated, jumper J4 can be used additionally to re-connect the swivel angle
command value input from inputs 14c (+) and 16c (-) to connections 18c (+) and
20c (-).
This reduces the wiring effort for a master/slave circuit (see Chapter 5.12 Master/
slave operation on page 34. The master/slave function can be deactivated at any
time during operation.
Table 15: Activation/deactivation of pressure controller OFF and master/slave

function
Function PLC-in pin 18a Jumper J4
Pressure controller ON/OFF OFF
Master/slave ON/OFF ON
Factory setting: J4 not set
Attention:
The function of pressure limitation is no longer effective when the pressure
controller is deactivated!
Utilization of the analog input at Depending on the variant, the analog input with connections 18c(+) and 20c(-) is
18c/20c (J2) used for different purposes.
Version without power limitation (VT 5041-3X/1... or VT 5041-3X/2...)

For the master/slave operating mode, the actual swivel angle value of the master
can be read in at this input. When the operating mode slave is activated (by
means of switching input 18a) the input is automatically connected to the swivel
angle controller, and the pressure controller is deactivated. The pump is then
operated exclusively under closed-loop swivel angle control.
Version with power limitation (VT 5041-3X/3...)

With the variant of the VT 5041-3X with power limitation, the analog value is taken
as power command value. For further notes on power limitation, please read
Chapter 5.11.9 Power limitation on page 33.
Jumper (J8) If control electronics VT 5041-3X is installed as replacement for VT 5041-2X in an

existing system, jumper (J8) must always be set.
For new systems, the jumper must be configured depending on the type of wiring.
For more details, see Chapter 7.6.4 Connecting the valve position transducer on
page 56.
Gain of pressure controller (J11) This adjustment option is provided for reason of compatibility with control
electronics VT 5041-2X. If control electronics VT 5041-3X is to be used as
substitute for VT 5041-2X, it is possible to select the same gain as with the control
electronics of series 2X.
Jumper J11 assumes the same function on both control electronics (series 2X
and 3X).
Together with switches S3.7 and S3.8 these jumpers can be used to change
the gain of the pressure controller. More details are explained in Chapter
8Commissioning on page 70.
Factory setting: J11 set
Reference for actual pressure value The jumper must not be set irrespective of the application at hand and for reason
signal (J16) of compatibility with control electronics VT 5041-2X.
Commissioning
Jumper J16 can be used to connect the 0-V reference for the actual pressure
value signal to 10c (= reduced wiring effort).
Note: If 0 V is externally connected to 10c by means of a jumper, J16 must not
be set.
8.1.5 Switching on the supply voltage for the control electronics

ff B
efore switching the supply voltage on, thoroughly re-check all cable
connections (including any intermediate terminals, if provided).
Measurements at the front-sided measuring sockets or at the rear male or
female multi-point connector may only be taken with instruments having an
internal resistance of Ri > 100 kOhm.
The controller card may only be plugged or withdrawn when disconnected
from the power supply.
The switch-on sequence of electronics/hydraulics is described in Chapter 5.12.1

Activation sequence of electronics/hydraulics on page 37.
For this, the drive motor of the pump must be switched off. For initial
commissioning, the following proceeding is recommended:
ff Switch on voltage supply
The green LED Ub signals that the voltage supply is active
ff Activate enable
The green LED En. signals that the enable is applied
The red LED Err. (fault) must not be ON
If this state is not achieved, a fault must have occurred.

Possible faults:
The green LED Ub is out
ff Check the supply voltage
ff Check fuse F1
The red LED Err. (fault) is ON

ff The enable contact must be made, i.e. En. is ON
ff Measure the actual pressure value at measuring socket 2 (must be ca. 0 V)
In the case of a negative voltage of less than ca. -1 V or voltages greater than ca.
+12 V a fault message is output.
ff Check the signal path to the pressure transducer.
The signal range of the pressure transducer must correspond to the

configuration of switch S2! (Current, voltage, zero point).
The swivel angle indicator shows ca.100 %, and a voltage of ca. 8...10.5 V
must be measurable at measuring socket 4. (The pump, which is at rest, is
mechanically fully swiveled out by the spring in the counter-piston).
If the swivel angle indicator shows minus 100 or ca. -10 V is measured at
measuring socket 4, inspect the cabling of the swivel angle transducer.
When monitoring of the control error was activated (J9 ON), check the valve
command value at socket 5. Should the valve command value exceed an
amount of 4 V, the command values must be adjusted or J9 set to OFF for
trial and testing.
Commissioning
If none of the points above applies, check the connection of the valve position
transducer and the solenoid.
The voltage symmetry of the high-response valves internal voltage may be
outside the limit value. You can check the voltage at connections 24a (+15 V)
and 20a (-15 V).
After having detected the fault:

ff Switch off supply voltage
ff Eliminate fault
ff Switch on supply voltage and grant enable
Check the connection of command ff Provide command values for (e.g. +1.5 V) and swivel angle (e.g. +2.5 V).
values for pressure and swivel ff At measuring socket 1, +1.5 V must be measured; at measuring socket 3,
angle +2.5V. If not, inspect the cabling of the command value source.
Check the zero point of the pressure When adjusting the zero point, always see to it that the hydraulic system is
transducer depressurized at the place of measurement of the pressure transducer!
ff Check the voltage at measuring socket 2: 0 V 50 mV
ff If required, calibrate using potentiometer R1 (at the front)
8.1.6 Switching on the drive motor of the pump

1. Close all directional valves
2. Before switching the motor on, apply the following command values to control
electronics VT 5041-3X:
Pressure command value (pcomm) = 1.0 V 31.5 bar
Flow command value (comm) = 2.0 V 20 %
These values are valid when our standard transducer is used with a measuring
range of 0...315 bar.
In this state, the control electronics VT 5041-3X signals a fault (excessive
control deviation). When the electronics works properly, the fault message
disappears when the motor is switched on (control error now equal to zero).
ff Before further commissioning, let the hydraulic oil warm up to operating
temperature.
ff For initial commissioning, limit the pressure to max. 50 bar.
8.1.7 Checking and correcting the valve zero point

ff All directional valves must be closed, no oil flow permitted!
ff Provide a swivel angle command value of 5 V (measuring socket 3 +5 V)
ff Set an operating pressure of ca. 100 bar by increasing the pressure command
value (read off from the pressure gauge)
ff The correct setting of the valve zero point can be measured between
measuring sockets 1 and 2. At an operating pressure of 100 bar, a voltage
value of 0V0.05V must be measurable at measuring sockets 1 and 2.
If the control error is greater (caused by, for example, differing cable lengths),
correct the value by adjusting potentiometer R6 at the front panel.
Adjust R6 so that a voltage of 0 V is measured between measuring sockets 1
and 2.
Commissioning
8.1.8 Bleeding the pre-load valve
WARNING
High pressure in the case!
Risk of injury! High pressure in the interior can cause parts and jets of hydraulic
fluid to be ejected when the bleed screw is opened.
ff Do not turn the bleed screw out too far (max. 2 turns)!
When a pump unit is operated with a pre-load valve, this valve must be air-bled
for the initial start-up, if the pump does not deliver or aspire oil. Bleeding is not
required, when the pump displaces oil. Bleed the pump while the system is
running at low operating pressure. To this end, loosen the screw (see Figure
below) by a maximum of 2 turns and wait until bubble-free oil flows out. Then,
re-tighten the screw.
Bleed screw
Fig. 32: Bleeding of the pre-load valve
8.1.9 Adjusting the operating pressure

The operating pressure is the pressure level that the pump system is to generate
as maximum value in the system. The control electronics converts the signal level
of the pressure transducer connected to the pump system into the normalized
level of 0...10 V and passes this actual pressure value on to the pressure
controller. The converted actual pressure value can be measured at measuring
socket 2.
Depending on the signal output of the pressure transducer, the signal adjustment
(switch S2) of the control electronics must be preset.
The factory setting of signal adjustment is configured to the signal range of
0+10 V.
Some examples:
4...20 mA is converted into 0...10 V
1...10 V is converted into 0...10 V
The pressure controller of the VT 5041-3X compares the level at the command
value input (0...10V; measuring socket 1) with the converted actual pressure
value (0...10 V; measuring socket 2).
If the measuring range of the pressure transducer does not correspond to
the operating pressure, it is not the operating pressure value that is used for
Commissioning
controlling when the maximum pressure value is provided as command value

(+10 V), but the final value of the pressure transducers measuring range.
Two options are provided for adjustment:
Pressure command value adjustment
Actual pressure value adjustment
Pressure command value With pressure command value adjustment, the pressure command value is
adjustment normalized to the measuring range of the pressure transducer and fed forward
accordingly.
With this method, no adjustments need to be made on control electronics
VT5041-3X.
Example:
Measuring range of standard
pressure transducer: 0... 315 bar
Selected operating pressure: 250 bar
The following is valid for the pressure 10 V/315 bar = 31.7 mV/bar (= factor)
command value provision: 250 bar x 31.7 mV/bar = 7.94 V
i.e. the pressure command value is normalized to the factor of 31.7 mV/bar;
in order to provide the operating pressure as pressure command value, a
pressure command value of 7.94 V must be generated.
General formula:
Factor: 10 V/measuring range of PT
Pressure command value [bar]: Pressure x factor = pressure command value [V]
PT = pressure transducer
Actual pressure value adjustment With actual pressure value adjustment, the actual pressure value is normalized to
the operating pressure.
With the factory setting, the control electronics VT 5041-3X.. converts the signal
of the pressure transducer internally into the range of 0...+10 V.
To change the signal range (= gain) of the actual pressure value, use
potentiometer R2 (front panel) of control electronics VT 5041-3X.
Proceeding while the system is in operation:

1. Close all directional valves. No oil flow permitted!
2. Provide a swivel angle command value of >+5 V (measuring socket 3 = +5 V)
3. Set the pressure command value to 5 V (= half operating pressure)
4. Then turn potentiometer R2 until the pressure gauge that measures the pump
pressure indicates half the operating pressure.
For checking purposes: The provision of a command value of +10 V must

result in the full operating pressure ( 3 bar).
Commissioning

Adjustment to the connected oil The oil volume between the consumer and the pump has a decisive influence on
volume the control dynamics of the pressure control loop. Switches S3.1 to S3.3 can be
used to adjust the controller to the connected oil volume; whereas when switching
input Switch Td (22c) is activated, switches S3.4 to S3.6 become active.
With the factory setting, switches S3.1 to 3.6 are in the OFF position
D1: Like VT 5041-2X
Adjustment to great oil volumes
Fig. 33: Adjustment to the connected oil volume
When compared with the predecessor control electronics VT 5041-2X, the

function Switch Td with an additional volume adjustment option was newly
added.
When substituting control electronics VT 5041-2X with the VT 5041-3X match
jumpers J3 to J5 with switches S3.1 to S3.3.
The changeover via switching input Switch Td is also possible while the SYDFE1
control system is running.
Table 16: Volume adjustment

Volume adjustment of Switch S3
pressure controller
.1 .2 .3
td = OFF
5.0 OFF OFF OFF
7,5 OFF ON OFF
10 ON ON OFF
15 ON OFF ON
20 OFF ON ON
25 ON ON ON
Pressure controller Switch S3

td = ON
.4 .5 .6
12.5 OFF OFF OFF
30 OFF ON OFF
45 ON ON OFF
60 ON OFF ON
75 OFF ON ON
90 ON ON ON
Commissioning
Gain of the pressure controller Under normal conditions, it is not required to change the P-component of the
pressure controller. However, if you hear a rough pump noise within the upper
pressure range, you can reduce the gain of the pressure controller.
Table 17: Reduction of the P-gain

P-gain of pressure Switch S3
controller
.7 .8 J11
8.0 OFF OFF OFF
4.8 ON OFF OFF
4 OFF OFF ON
3 OFF ON ON
2.4 ON OFF ON
2 ON ON ON
With the factory setting, switches S3.7 and 3.8 are in position OFF; jumper 11 is set (ON)
8.1.11 Checking swivel angle sensing

Testing swivel angle zero ff The directional valve(s) must be closed
ff Provide a swivel angle command value of 5 V
ff Provide a pressure command value of 20 bar
ff Following the example on page 68 (31.7 mV/bar), apply a pressure command
value of 0.634 V.
The resulting pressure must be 20 bar (3 bar)
ff Check, whether a voltage of 0 V 0.1 V can be measured at measuring socket

4
ff Correct any deviations by means of potentiometer R8 (front panel)
Setting swivel angle 100 % The maximum swivel angle of the pump can be adjusted in two different ways.
Adjustment while the system is running:
1. Apply a swivel angle command value >10 V, pressure command value 5 V
2. Direct the full flow via the consumer or flowmeter: e.g. activate hydraulic motor
or set pressure relief valve to ca. 20 bar
3. Adjust potentiometer R9 so that a voltage of +10.0+0.01 V can be measured
at measuring socket 4.
Adjustment while the drive motor is switched off:

1. Switch the hydraulics off and wait for about 5 minutes until the pump has
swiveled out mechanically (wait until pressure is completely reduced). You
can also observe the actual swivel angle value (measuring socket 4) and wait
until the actual swivel angle increases to a value below the maximum value
and then remains constant.
2. Measure the actual swivel angle value and adjust it to +10 V +0.01V
(corresponds to maximum stroke) by means of potentiometer R9.
3. In some cases, the pump will not swivel to the limit stop (maximum value).
For this reason, briefly switch the motor on, then switch off, wait until the pump
has swiveled out and then measure the actual swivel angle value. If a higher
voltage is measured, correct the value. Repeat this procedure several times.
Commissioning
8.1.12 Adjusting the power limitation (with VT-5041-3-3X/... only)

By means of power limitation you can determine the maximum power
consumption of the pump in order not to overload the drive motor.
Setting a constant power limitation The calculated power limit can be adjusted by means of potentiometer R3 (front
using potentiometer R3 panel) and measured directly at measuring socket 8 (front panel). The value
range of 0+10 V corresponds to a calculated power of 0+100%. The
adjustment at the measuring sockets can also be made while the hydraulics is
switched off. Switching output 18a or the LED lamp on the front panel becomes
High, when the actual swivel angle value (flow) and the actual pressure value are
sufficiently high so that the power limitation responds. When the hydraulics is
switched off or shut off, switching output 18a is not active.
Factory setting for R3: 10 V = 100 % (right-hand positive stop)
External provision of the power limit ff Check that jumper J2 is set in position 2-3
ff Turn potentiometer R3 (front panel) to the left-hand positive stop (factory
setting is right-hand positive stop +100 % power limit)
ff By applying a voltage within the range of 0+10 V to terminals 18c(+) and
20c(-) a power limit of between 0 % and 100 % can be set. The selected value
can be checked at measuring socket 8 (front panel).
Example Calculation of the rated pump power

Motor power PM = 15 kW
Speed n = 1500 min-1
Displacement VG = 100 cm (pump size)
Maximum pressure pmax. = 315 bar
Efficiency mh = 1 (theoretical value)
Maximum pressure = pressure [bar], at which the actual pressure value output of
the control electronics VT 5041-3X outputs a value of +10 V at measuring socket
2 (= actual pressure value).
VG [cm3] n [min-1] pmax [bar]

P100% = [kW]
600,000 mh
P100% = 78.75 kW
Calculation of the ratio
PM
(p )max = 100 % = 19 %
P100%
In this case, the power limit would have to be set to 19 %, i.e. 1.9 V.
8.1.13 Performing a functional test

Once you have tested the hydraulic fluid supply, you must perform a functional
test on the machine or system. The functional test should be carried out according
to the instructions of the machine or system manufacturer.
Before delivery, the SYDFE1 control system is checked for operability in
accordance with the technical data. During commissioning, it must be ensured
that the SYDFE1 control system was installed into the machine or system in
accordance with the plans and drawings. Use the swivel angle indicator to check
whether the SYDFE1 control system correctly swivels in and out during operation.
Commissioning
The position of the swivel angle indicator and the assignment of the swiveling
direction to the direction of rotation and control can be found in the associated
technical data sheets.
8.1.14 Bleeding during commissioning or after longer standstill

periods
Just like during commissioning you have to bleed the SYDFE1 control system
also after longer periods of standstill in order that the pump can build up pressure
directly after the electric motor starts up. The necessity for this depends, however,
also on the installation orientation of the pump.
You can bleed the system manually by opening the pressure line at a suitable
point (e.g. minimess port, valve, etc.). When an unloading valve to tank is
installed (quasi pressureless start-up), this procedure can also be automated
when the electric motor starts up: The valve merely needs to be activated briefly;
a continuous pressureless start-up as described in the following is not required.
If a SYDZ pre-load valve is installed and the pump does not build up pressure
or displace hydraulic fluid, this valve must be bled additionally at point P as
described in section 8.1.8 Bleeding of the pre-load valve on page 67.
8.2 Recommissioning after standstill

Depending on the installation and ambient conditions, changes may occur in the
system which make recommissioning necessary.
Among others, the following criteria may result in the necessity for
recommissioning:
Air in the hydraulic system
Water in the hydraulic system
Aged hydraulic fluid
Contamination
ff For recommissioning, proceed as described in Chapter 8.1 Initial

commissioning on page 60.
8.3 Running-in phase
NOTICE
Too low viscosity!
Risk of damage! The increased temperature of the hydraulic fluid during the
running-in phase can cause the viscosity to drop to impermissible levels.
ff Monitor the operating temperature during the running-in phase.
ff Reduce the loading (pressure, speed) of the SYDFE1 control system, if
impermissible operating temperatures and/or viscosities occur.
Bearings and sliding surfaces are subject to a running-in phase. Increased friction
at the start of the running-in phase results in increased heat generation which
decreases with increasing operating hours. The volumetric and mechanical-
hydraulic efficiency rises as well by the end of the running-in phase of approx. 10
operating hours.
Operation
9 Operation
The SYDFE1 control system is a component which requires no adjustments or
changes to be made during operation. For this reason, this chapter of the manual
does not contain any information on adjustment options. Only use the product
within the performance range provided in the technical data. The machine or
system manufacturer is responsible for the proper engineering of the hydraulic
system and its control.
Maintenance and repair
10 Maintenance and repair
10.1 Cleaning and care
NOTICE
Solvents and aggressive detergents!
Aggressive detergents may damage the seals of the SYDFE1 control system
and cause them to age faster.
ff Never use solvents or aggressive detergents.
Ingress of contaminants and fluids!

This will result in the fact that the safe operation of the SYDFE1 control system
can no longer be ensured.
ff When carrying out any work on the SYDFE1 control system observe strictest
cleanliness.
ff Never use high-pressure cleaners.
For cleaning and care of the SYDFE1 control system, observe the following:
ff Plug all openings with suitable protective caps/devices.
ff Check that all seals and plugs of the plug-in connections are securely seated
to ensure that no moisture can enter the SYDFE1 control system during
cleaning.
ff Use only water and, if necessary, a mild detergent to clean the SYDFE1
control system.
ff Remove coarse dirt from the outside of the system and keep sensitive and
important components, such as solenoids, valves and displays, clean.
10.2 Inspection
In order that the SYDFE1 control system will work reliably and for a long time,
Rexroth recommends that you inspect the SYDFE1 control system regularly at the
following maintenance intervals and document the following operating conditions:
Table 18: Inspection schedule

Work to be carried out Interval
Hydraulic system Check level of hydraulic fluid in the tank. Daily
Check operating temperature (comparable load Weekly
state).
Analyze quality of the hydraulic fluid. Annually or every
2000h (whichever
occurs first)

SYDFE1 control Inspect the SYDFE1 control system for leakage. Daily
system Early detection of hydraulic fluid loss can help
identify and rectify faults on the machine or
system. For this reason, Rexroth recommends
that the SYDFE1 control system and the system
as a whole always be kept in a clean condition.
Check the SYDFE1 control system for Daily
generation of noise.
Check mounting elements for proper fit. Monthly
Inspect all mounting elements while the system
is switched off, depressurized and cooled down.
10.3 Maintenance
SYDFE1 control systems require little maintenance when properly used.
The service life of the SYDFE1 control system is heavily dependent on the quality
of the hydraulic fluid. For this reason, we recommend changing the hydraulic fluid
at least once a year or every 2000 operating hours (whichever occurs first) or
having it analyzed by the hydraulic fluid supplier or a laboratory to determine its
suitability for further use.
The service life of the SYDFE1 control system is limited by the service life of the
built-in bearings. The service life can be requested on the basis of the load cycle
from the responsible Rexroth Service partner, see Chapter 10.5 Spare parts
below. Based on these details, a maintenance interval is to be determined by
the system manufacturer for the replacement of the bearings and included in the
maintenance schedule of the hydraulic system.
10.4 Repair
Rexroth offers a comprehensive range of services for the repair of Rexroth
SYDFE1 control systems.
Repairs of the SYDFE1 control system may only be performed by authorized,
skilled and instructed staff.
ff Only use genuine spare parts from Rexroth for repairing Rexroth SYDFE1
control systems.
Partially tested and pre-assembled original Rexroth assemblies allow for

successful repairs within a minimum of time.
10.5 Spare parts

When ordering spare parts, please indicate the material numbers of the relevant
spare parts. On some components, the material number is shown on a nameplate
or a label.
Please address all questions regarding spare parts to your responsible Rexroth
Service partner.
Bosch Rexroth AG
Service Hydraulics
Bgm.-Dr.-Nebel-Str. 8
97816 Lohr am Main
Tel: +49 (0) 9352 - 18 0
Fax: +49 (0) 9352 - 18 39 83
spareparts.bri@boschrexroth.de
For the addresses of foreign subsidiaries, please refer to

www.boschrexroth.com/adressen
ff Please state the following data from the nameplate on your order:
material number
serial number
production job order number
production date
10.5.1 Replacement of components

The replacement of some components of the SYDFE1 control systems is
described in the following.
Swivel angle sensor IW9 for Swivel angle sensor IW9 operates as inductor circuit according to the inductive
SYDFE1 systems principle and senses the mechanical stroke of the pump without wear. In the case
of faults in swivel angle sensing, both, the coil body and the mechanical parts are
easy to replace. If the settings of control electronics VT 5041-2X were not
changed, matching of the coil body is limited to mechanical clamping/fixing
(preferably in zero stroke operation) while controlling the electrical zero point on
the control electronics
Table 19: Available spare parts

Material number Description
R910910848 Coil body IW9 and core
R910986163 Coil body IW9 and core accommodated in the sensor housing, but
without the driver to be installed into the pump
R910947340 Complete kit (incl. seal, screws and tapered catch)
Swivel angle sensor IW9-LIN-1X General

for SYDFE1 systems The prod is a sensitive component and must therefore be handled with care. In
particular with regard to the magnetic properties, the prod must not be subjected
to hard impacts and must be kept away from metal parts! Keep the prod in the
original packaging until it is installed in the pump housing.
Installation of the swivel angle sensor IW9-LIN-1X

Tighten sensor to 25 +5 Nm (27 A/F)
Adjust the swivel angle sensor.
Measure the actual swivel angle value and set it to 10.05 V +0.01V
(corresponds to maximum stroke) using potentiometer G
In some cases, the pump will not swivel out to the limit stop. For this reason,
switch the motor briefly on, then switch off, wait until the pump has swiveled
out and then measure the actual swivel angle value. If a higher voltage is
measured, correct the value. Repeat this procedure several times.
Seal kits for the pump Stating the Mat. no. of the pump you can order seal kits, which are either tailored
to certain individual components or offered as complete packages.
Pilot valve VT-DFP-x-2X The pilot valve is a component, which is sensitive to contamination. When
replacing it, take care that no contaminants can enter fluid-carrying parts of the
valve and the pump. To replace the pilot valve loosen the 4 screws at the
recessed corners of the nameplate on the pilot valve. When replacing the pilot
valve, check the valve zero point and correct it, if necessary, see Chapter 8.1.7
Testing and correcting the valve zero point on page 66:
Pre-load valve SYDZ0001 To replace the pre-load valve, loosen the mounting screws and remove the
pre-load valve.
Mounting screws
Fig. 34: Mounting bores: left-hand side (round) for NG18, 28, 25; right-hand side
(rectangular) for NG 71, 100, 140
When mounting a new pre-load valve, take care that the seal on the pump side to
the pre-load valve is positioned in the recess provided for this purpose. Tighten
the mounting screws to the following torque:
Sizes 18, 28 and 45: 45 Nm
Size 71: 55 Nm
Sizes 100 and 140: 100 Nm
After having mounted the pre-load valve, connect the high pressure and case
drain oil pipes as described in Chapter 7.3 Installation positions and piping of
SYDFE1 systems on page 44. During re-commissioning, bleed the pre-load
valve. Notes on the bleeding procedure can be found in Chapter 8.1.8 Bleeding
the pre-load valve on page 67.
Decommissioning
11 Decommissioning
The SYDFE1 control system is a component that does not require
decommissioning. For this reason, this chapter of the present instructions does
not contain any information.
For details about how to demount or replace your SYDFE1 control system, please
refer to the following Chapter 12 Demounting and replacement,
12 Demounting and replacement
12.1 Required tools

Demounting can be carried out with standard tools. You will not require any
special tools.
12.2 Preparing demounting

1. Decommission the entire system as described in the general instructions for
the machine or system.
2. Relieve the hydraulic system according to the instructions of the machine or
system manufacturer.
12.3 Demounting the SYDFE1 control system

Proceed as follows to demount the SYDFE1 control system:
1. Make sure that the hydraulic system is depressurized.
2. Check that the SYDFE1 control system has cooled down sufficiently so that it
can be demounted without any risks.
NOTICE! Discharged or spilled hydraulic fluid!

Environmental damage and contamination of the groundwater!
ff When filling in and changing the hydraulic fluid, always place a catch pan
under the SYDFE1 control system.
ff Observe the information in the safety data sheet for the hydraulic fluid and the
specifications provided by the system manufacturer
1. Loosen the lines and collect the escaping hydraulic fluid in the collector
2. Demount the SYDFE1 control system. Use suitable lifting gear for this.
3. Drain the SYDFE1 control system completely.
4. Plug all openings.
Disposal
12.4 Preparing the components for storage or further

use
ff Proceed as described in Chapter 6.2 Storing the SYDFE1 control system on
page 41.
13 Disposal
13.1 Environmental protection

When disposing of the SYDFE1 control system, observe the following points:
1. Drain the control system completely.
2. Therefore, dispose of the SYDFE1 control system, the hydraulic fluid and the
packaging material in accordance with the national applicable regulations in
your country and the safety data sheet for the hydraulic fluid.
3. Disassemble the control system to recycle the individual parts. Please
separate by:
Cast iron
Steel
Non-ferrous metal
Electrical waste
Plastics
Seals
14 Extension and conversion

The SYDFE1 control system may only be converted or extended in the cases
described below using genuine Rexroth SYDFE1 components. Other conversions
or extensions, also the readjustment of lead-sealed adjustment potentiometers
render the warranty void. The replacement of a component with a component of
the identical design is described in Chapter 10.5 Spare parts on page 76.
The SYDFE1 control system may be extended by adding an SYDZ pre-load
valve. Please ensure that the size of the pre-load valve and the size of the pump
are identical.
Troubleshooting
15 Troubleshooting
The following table may assist you in troubleshooting. The table is not exhaustive.
In practice, problems which are not listed here may also arise.
Generally, the state of the SYDFE1 control system is indicated on the front panel.
Fig. 35: Indicator lamps on the front panel
Green LED Ub This LED is illuminated when the correct voltage supply is provided for the control
electronics VT5041-3X.
If this LED is not illuminated, check the following:
Voltage supply available (U = 21...35 V)
Fuse F1
Red LED Err This LED signals a collective fault (or missing enable).
The fault signal can also be measured at pin 2c of the female multi-point
connector and can be used for signaling this to a higher-level control.
The following is valid here:
0 V fault
24 V no fault
The fault signal refers to a collective fault and is composed of the following
individual faults:
Monitoring of actual pressure value sensing
Monitoring of swivel angle sensing
Monitoring of actual valve value sensing
Enable not granted
No supply voltage present or fuse F1 defective
When monitoring of the control error is activated (jumper J9), excessive control
error (valve command value > +4 V or < -4 V) for longer than 1 sec.
Troubleshooting
Which fault is present? The individual faults are signaled on the printed-circuit board of the control
electronics (provided that the view to the indicator lamps is not obstructed).
1
2
3
4
5
6
7
8
9
Fig. 36: Fault signals on the printed-circuit board
1 Excessive permanent control error

2 Break of valve position transducer cable (secondary)
3 Break of valve position transducer cable (primary)
4 Break of swivel angle position transducer cable
5 Actual pressure value error
6 Actual valve value error (out of range)
7 Fault of internal voltage supply (unbalance)
8 Actual swivel angle value error (range exceeded)
9 Fault of internal voltage supply (undervoltage)
Neither the individual faults nor the collective fault are saved and always reflect
the momentary state.
Example If a loose connection at a plug-in connector of the swivel angle transducer (IW9)
results in the temporary detection of a fault, this individual fault will trigger the
issue of a fault signal.
Depending on the configuration of jumper J1 the following will happen:
J1 ON, i.e. shutdown of the valve output stage
In this case, the relevant fault results in the shutdown of the valve output stage,
that is, the activation of the pilot valve is interrupted.
This causes the position of the valve spool to leave the permitted range of the
actual valve value and thus results in signaling of the individual fault v-actual
(fault: actual valve value out of range).
A SYDFE1 system with internal supply will change over to zero stroke operation
(ca. 8...12 bar). The command values applied (pressure, swivel angle) will not be
Troubleshooting
used for controlling. Accordingly, depending on the command value provision, the
individual fault message continuous control error will be signaled as well.
In this case, consequential faults may, under certain circumstances, also be
signaled in addition to the original fault.
J1 OFF, i.e. exclusively signaling of a fault, no shutdown.

In this case, the relevant fault results in brief signaling (loose connection) of
the fault, which is indicated by the error LED on the front panel of the control
electronics as well as well as by PLC output 2c.
15.1.1 Fault analysis

If the LEDs on the control electronics can be viewed without obstruction, it is
sufficient to check the individual fault(s) as indicated by the LEDs. If you cannot
view the LEDs or if the fault cannot be rectified in this way, check the following
points:
Preparations
ff Unplug the motor fuse
ff Switch on the pump electronics
Enable contact made? Check the connection between female multi-point connectors 26c and 32a.
Monitoring of actual pressure value The actual pressure value, which can be measured at measuring socket 2, is
sensing monitored for the permitted range, which is between -0.5 V and +11.5 V.
Possible faults can be an interrupted signal cable, missing voltage supply to the
sensor or an incorrectly adapted actual pressure value signal.
Actual pressure value < -0.5V
ff Check cabling and voltage supply to the pressure transducer
ff Correct zero point of the actual pressure value input (R1)
Actual pressure value > +1.5V

ff Check cabling to the pressure transducer
ff Check signal output of the pressure transducer
Monitoring of swivel angle sensing Break in swivel angle position transducer cable
The monitoring feature recognizes faults in the cabling between the swivel
angle sensor of the pump (IW9) and control electronics VT5041-3X.
Out of range
If the actual swivel angle value (socket 4) is outside the permitted range of
11 V, a fault signal is generated.
When the hydraulics is switched off, the swivel angle of the pump should be
+10 V when properly adjusted.
Possible faults can be an interrupted signal cable or an incorrectly matched
actual swivel angle value.
Moreover, the resistance of cables can be measured while the connector is

plugged in on the swivel angle sensor of the pump (IW9).
ff Switch voltage off
ff Remove control electronics VT 5041-3X from the rack
Female multi-point connector 14a to 10a: ca. 36 Ohm
Troubleshooting
Note:
This measurement will not provide any information on the correct wiring
of counter-clockwise and clockwise rotating pumps (see also Chapter
7.6.5Connecting the swivel angle transducer on page 57).
Monitoring of actual valve value P

rimary and secondary side of the position transducer
sensing The signals to the position transducer (primary side) as well as from the
position transducer (secondary side) are checked for plausibility. Should one
of the two LEDs be lighted, check whether the position transducer is wired
correctly.
VT 5041-3X Valve position transducer

Primary side Connection 8a/22a Connection 1 and 2
Secondary side Connection 4a/6a Connection 3 and 4

Signal level of position transducer position > +11V
When the valve is not activated (e.g. no enable given for the valve or the
solenoid connector is unplugged), the actual valve value will leave the
permitted operating range. This will result in an individual fault.
Moreover, the resistance of the cables can be measured with connectors plugged
in on the valves.
ff Switch voltage off
ff Remove control electronics VT 5041-3X from the rack
Female multi-point connector 28c to 30c: ca. 2-4 Ohm (solenoid)
Female multi-point connector 4a to 6a: ca. 103 Ohm (position transducer)
Female multi-point connector 8a to 6a: ca. 115 Ohm (position transducer)
Monitoring of the control error This monitoring function is active only when jumper J9 is set (= ON).
The monitoring feature, which was newly added compared with control electronics
VT 5041-2X, continuously checks the valve command value (= control difference
x controller gain) and signals a fault, as soon as the amount exceeds the value of
4 V, which can be measured at socket 5.
To remain compatible with series 2X control electronics in terms of function, this
monitoring feature is deactivated with the factory setting (jumper J9 open).
By setting jumper J9 you can add this fault signal to the collective fault signal.
It must be noted that when this fault signal is deactivated, the LED v-soll on
the printed-circuit board continues to signal a control error as fault, but will not
evaluate it.
Monitoring of the internal voltage The voltages of +15 V and -15 V generated by the own power supply unit of the
supply VT5041-3X are monitored for the following levels.
Monitoring of internal voltage +15 V for values less than 10 V
(fault is signaled by LED, see Fig. 36, item 9: Undervoltage +15 V)
Excessive difference between +15 V and -15 V (= unbalance)
Should one of the two above-mentioned individual faults be present, check,

whether too high a load or possibly a short-circuit is present at outputs 20a (-15V)
and 24a (+15V).
ff Check auxiliary voltages at control electronics VT 5041-3X (reference = 22a)
Female multi-point connector 20a = -15 V (-14.1 V-15.3 V)
Female multi-point connector 24a = +15 V (+14.1 V+15.3 V)
Troubleshooting
Further possible cause of fault Should the pump generate pressure in an uncontrollable manner without a fault
signal being issued by control electronics VT5041-3X, check the control valve
VT-DFP- for jamming.
ff Unplug solenoid connector
ff Measure actual valve value at socket 6
With a non-jammed valve, the actual valve value (socket 6) must now be
within the range of +10 V to +15 V. Otherwise, the valve is likely to be
jammed.
ff Replace valve
After having rectified the fault ff Switch the voltage off and on (clearing of the fault signal)
ff If the fault signal is no longer present, switch the pump off
ff Activate the motor fuse
ff Switch the pump on
15.1 How to proceed for troubleshooting

ff Always act systematically and targeted, even under pressure of time. Random
and imprudent disassembly and readjustment of settings might result in the
inability to ascertain the original cause of fault.
ff First obtain a general overview of how your product works in conjunction with
the entire system.
ff Try to determine whether the product worked properly in conjunction with the
entire system before the troubles occurred.
ff Try to determine any changes of the entire system in which the product is
integrated:
Were there any changes to the products operating conditions or operating
range?
Were there any changes or repairs on the complete system (machine/
system, electrics, control) or on the product? If yes, which?
Was the product or machine used as intended?
How becomes the malfunction apparent?
ff Try to get a clear idea of the error cause. Directly ask the (machine) operator.
ff If you cannot rectify the error, contact one of the contact addresses which can
be found at:
Troubleshooting
15.2 Malfunction table

Table 20: Malfunction table for SYDFE1 control systems
Fault Possible cause Remedy
Error message present: Enable not granted: Indicator lamp En. is out. Apply 24 V to contact 26c
Indicator lamp Err. on the front panel
of the VT 5041-3X is ON Supply voltage missing or fuse F1 defective: Apply 24 V to contact 32a, connect 28a to
Indicator lamp Ub is out ground (0 V)
Cable break of the swivel angle sensor cable Check wiring (see 7.6.5 Connecting the swivel
angle sensor on page 57)
Cable break of the valve position sensor cable Check wiring (see 7.6.4 Connecting the valve
position transducer on page 56)
Cable break of the proportional solenoid cable Check wiring (see 7.6.6 Connecting the
solenoid of the proportional valve on page 58)
When control error monitoring is activated For further notes, see page 62
(jumper J9 set/ON), excessive control deviation
(valve command value > +4 V or <-4V) for
longer than 1 sec.
Defect or short-circuit of auxiliary voltages on Contact Rexroth Service
the control electronics
Humming noise in the pressure Air cushion around the sensor Thoroughly bleed control system, pre-load valve
control or fluctuations in pressure/flow (see page 68) and pipes
Problem with the cable shield Ground shield
Unfavorable place of mounting/mounting Change place of installation (e.g. suspended

technique of the pressure transducer mounting, no minimess line, no throttling point
between pump and pressure transducer)
Unsuitably high gain of the actual pressure Reduce weighting of the actual pressure value
value and pressure command value, see page 65
Screaming noise Oil level in the tank too low; pump partly aspires Top up oil
air
Pump aspires air Change routing of the suction line
Suction line leaky Seal suction line

Pump cavitates when pressure is reduced Optimize controller, reduce command value via
Diagnosis: Measure, whether overshoots occur a ramp or in steps.
in the pressure line at individual pressure levels,
e.g. pressure almost 0 bar and, at the same
time, negative swivel angle
Fluid in the tank mixed with air; cooling and/or Seal
filtration circuit leaky
Troubleshooting

Other unusual noise Input speed too high Machine or system manufacturer
Wrong direction of rotation Machine or system manufacturer
Insufficient suction conditions, e.g. air in the Check that shut-off valves are open
suction line, insufficient diameter of the suction
line, viscosity of the hydraulic fluid too high, Machine or system manufacturer (e.g. optimize
suction height too great, suction pressure too inlet conditions, use suitable hydraulic fluid)
low, foreign body in the suction line Thoroughly air-bleed control system, fill suction
line with hydraulic fluid
Remove any foreign bodies from the suction line
Improper mounting of the control system Check mounting of the control system according
to the instructions given by the machine or
system manufacturer. Observe tightening
torques.
Improper mounting of fitted parts, e.g. coupling Mount attachments in accordance with
and hydraulic lines the instructions of the coupling or fitting
manufacturer
Air in the pump or in the pre-load valve Bleed pump and pre-load valve
Wear of/mechanical damage to the control Replace control system, contact Rexroth
system Service
No or insufficient pressure (< 4 bar) Faulty mechanical drive (e.g. defective coupling) Machine or system manufacturer
Hydraulic fluid not within the optimum viscosity Use suitable hydraulic fluid (machine or system
range manufacturer)
Drive unit defective (e.g. hydraulic motor or Machine or system manufacturer
cylinder)
Wear/mechanical damage Replace control system, contact Rexroth
Service
Pressure static, ca. 5...12 bar, cannot Supply voltage not within the permissible range Check, whether all connectors are plugged on
be changed (21.6...33.6) the pilot valve
Diagnosis: Is the actual swivel angle value (12c)
0Volt? If yes, is the supply voltage missing? Check voltage at the control electronics
Command value for pressure, swivel angle or If you use, for example, exclusively closed-
power (optional) is 0 bar or 0 %, respectively loop pressure control, connect the swivel angle
command value (14c/16c) to +10 V...UB
The potentiometer for power limitation (optional)
must not be on the left-hand limit stop
Swivel angle sensor defective Inspect swivel angle sensor, see page 70
Spool jams in pilot valve Contact Rexroth Service
Troubleshooting

Pressure too low (< 12 bar) Weighting of the actual pressure value is Adjust pressure command value and/or actual
incorrectly set pressure value (see page 68)
Diagnosis: Pressure command value (6c/4c)
Replace pressure transducer
and actual pressure value normalized (24c) are
equal and can be regulated Change place of installation of the pressure
transducer (do not install upstream of the pre-
load valve, rather close to the consumer)
Pressure transducer defective Replace pressure transducer
Diagnosis: Measure signal from pressure
transducer and compare with indication on the
pressure gauge
Control system does not work in closed-loop Increase swivel angle command value
pressure control
Increase power limit (see page 71)
Diagnosis: Pressure command value (6c/4c) is
less than actual value (24c) normalized. Check that hydraulic system is leak-free and the
consumption is not too great
Pilot valve defective Replace pilot valve
Pressure too high Weighting of the actual pressure value is Adjust pressure command value and/or actual
Diagnosis: Pressure command value (6c/4c)
and actual pressure value normalized (24c) are
equal and can be regulated Replace control electronics VT 5041-3X
Pressure transducer (PT) defective/not Connect pressure transducer correctly/replace
connected
Diagnosis: Measure signal from PT and
compare with indication on the pressure gauge
Flow too small Pressure controller active Increase pressure command value
Power limitation (optional) active Increase power command value (optional) (see
page 71)
Actual swivel angle acquisition maladjusted Re-adjust swivel angle sensor (see page 77)
Speed of drive too low (slip, incorrect frequency, Machine or system manufacturer
wrong motor)
Pump damaged (pump leakage too great) Replace pump
Wear/mechanical damage to the control system Replace control system, contact Rexroth
Service.
Troubleshooting

Drive motor switches off due to Excessive power consumption of the pump Reduce power command values (optional) (see
overloading page 71)
Reduce swivel angle command value
Check actual pressure value acquisition (see
page 68)
Protective overcurrent feature of the motor does Check setting and test function
not work properly
Spool jams in pilot valve Replace pilot valve, see page 77
Diagnosis: Disconnect central plug-in connector
X1 or supply voltage from pilot valve and test
whether the motor is still overloaded
Actual swivel value acquisition maladjusted or Check actual swivel angle acquisition, see page
does not work 70
VT 5041-3X defective Replace control electronics VT 5041-3X
Hydraulic fluid temperature too high Inlet temperature at control system too high Inspect system, e.g. malfunction of cooler,
insufficient hydraulic fluid in the tank
Pre-load valve opens Pressure must be lower than cracking pressure
Diagnosis: Pipe to the tank heats up of pre-load valve. Keep overshoots and
pressure pulsations to a minimum
Malfunction of pressure/pilot valves (e.g. high Contact Rexroth Service
pressure relief valve, pressure cut-off, pressure
controller)
Control system worn out Replace control system, contact Rexroth
Service
Technical data
16 Technical data
The technical data of your SYDFE1 system are contained in the following data
sheets:
SYDFE1 series 2X RE 30030
SYDFE1 series 3X RE 30630
The data sheet can be found on the Internet at
www.boschrexroth.com/ics
The preset technical data of your SYDFE1 control system can be found in the
order confirmation.
Annex
17 Annex
17.1 Address directory

For the addresses of our foreign subsidiaries and responsible sales companies,
please visit http://www.boschrexroth.com.
Contact for repairs and spare parts
Bosch Rexroth AG
Service Industriehydraulik
Brgermeister-Dr. Nebel-Str. 8
97816 Lohr am Main
Germany
Our spare parts catalog can be found on the Internet at

http://www.boschrexroth.com/spc
Here you can also find your technical contact
Contacts for repairs are listed on the Internet at:

http://www.boschrexroth.com/service
Ordering address for accessories and valves
Headquarters:
Bosch Rexroth AG
Hydraulics
Zum Eisengieer 1
97816 Lohr am Main
Germany
Phone +49 (93 52) 18-0
or the relevant sales subsidiary.
Addresses can be found on the Internet at:
http://www.boschrexroth.com

Annex
17.2 Position of adjustment elements of control electronics VT 5041-3X

Case drain Jumper Valve command Jumper Regenerative Jumper Function Jumper
compensation J6 J7 value monitoring J9 operation J3 J5 Pin 18a ** J4
OFF OFF OFF ON ON Ein ON OFF Pressure control
OFF
4% OFF ON OFF * OFF Aus OFF ON ON/OFF
6% ON OFF Master/Slave
ON
10 % ON ON ON/OFF
** Only with versions without
power limitation
(VT5041-3X/1... and
VT5041-3X/2...)
OFF (default)
ON *
Reference for position Valve shutdown in Jumper
transducer the event of a fault J1
Active OFF *
Inactive ON
OFF (default)
Reference for actual * compatible with VT 5041-2X
pressure value ()
0/
0''
Volume adjustment of pressure controller
Input switchTD = OFF Switch S3
Selection for Jumper P-gain of pressure Switch S3 Jumper .1 .2 .3
analog input at pin J2 controller .7 .8 J11 5.0 l OFF OFF OFF
18c bridge 8.0 OFF OFF OFF 7.5 l OFF ON OFF
Master actual swivel 4.8 ON OFF OFF 10.0 l ON ON OFF
1-2
angle value 4.0 OFF OFF ON 15.0 l ON OFF ON
External power 3.0 OFF ON ON 20.0 l OFF ON ON
2-3
limitation 25.0 l ON ON ON
2.4 ON OFF ON
2.0 ON ON ON Input switch TD = ON Switch S3
.4 .5 .6
Gain of actual Jumper
pressure value 12.5 l OFF OFF OFF
J10
30.0 l OFF ON OFF
Factor of 1 OFF
45 l ON ON OFF
Factor of 2 ON
60 l ON OFF ON
Signal adjustment Switch S2 75 l OFF ON ON
of actual pressure .1 .2 .3 .4 .5 .6 .7 .8 90 l ON ON ON
value
V 0...10 V OFF OFF OFF OFF OFF OFF ON ON
E 1...10 V OFF OFF OFF OFF ON OFF OFF ON
Explanations:
D 0...5 V OFF OFF ON ON OFF OFF ON ON
ON = Bridge closed
F 0.5...5 V OFF OFF ON ON ON OFF OFF ON
OFF = Bridge open
B 0...20 mA ON ON OFF OFF OFF OFF ON ON
= Factory setting
C 4...20 mA ON ON OFF OFF ON ON OFF OFF
Annex
17.3 Block circuit diagram of VT 5041-3X
Pressure command
value
[1] 1
6c
pcomm 0...10 V u
Reference 4c u
22c
Switch TD 0/+24 V Pressure controller
D1 [10]
pact 0...5 V 0...10 V Actual pressure value S3.1-3 P
[3] Adjustment
2 D2
0.5... 5 V 1...10 V
8c S3.4-6
0...20 mA 4...20 mA u
10c u
Reference
p act
R1
R2
Pressure controller OFF 18a Pressure control OFF

Master/slave 0/+24 V
> +11.5 V
J4
FE1-contr.1) Case drain com-
Version VT 5041-3X/1... or .../2... pensation
< - 0.5 V
3
[1] Adjustment
14c Active swivel angle com-
SWAcomm 10 V u + Swivel angle con-
16c u + mand value
Reference troller
7
Single pump/ [5] [6]
[1]
combination
MIN P
18c 1
SWAact/master or 10 V u 2 J2
20c u
Power limit Reference 3
0...+10 V 100 % 8
cw +
R3
ccw + DIV SWA max
0% p act
Power limit
Version VT 5041-3X/3...
Enable
F valve output stage
26c &
Enable 0/+24 V
30a
+UB
32a +15V Enable1)
= 0V
28a =
0V 26a -15V
Shield
32c 9 10
System ground Ub 1)
20a
15 V 22a
M0 24a
+15 V
Abbreviations for signals Diagnosis LEDs on printed circuit board

pcomm Pressure command value v-comm Continuous system deviation too great
pact Actual pressure value v-act Actual valve value fault - out of range
Switch TD Oil volume changeover p-ist Actual pressure value fault
SWAcomm Swivel angle command value swa-act Actual swivel angle value fault - out of range
SWAact Actual swivel angle value KB-TP Valve position transducer cable break primary
SWAact/master Actual swivel angle value of master KB-TS Valve position transducer cable break
secondary
FE1-contr. Pressure controller deactivated
KB-IW9 Swivel angle sensor cable break
+15 V US Undervoltage +15V (internal power supply unit)
Annex
8a 1 3
22a
Actual valve value M0 Valve position
6 transducer
[7]
= 2 4
4a
R6
Enable R7 6a
J8 OFF
Valve output stage 26a
Valve command value
5 [8] [9]
28c
p-control 1) u
P i 30c Proportional solenoid
[4]
Actual swivel angle value 14a (2)
MIN 4 [2]
= 10a 1 Swivel angle sensor
> +4 V
< -4 V IW9
R8 12a 2( )
R9 26a
t = 1 sec
u 24c
pact 0...10 V
u
p-act v-comm u 12c
u
SWAact 10 V
-control 1)
16a
Swivel angle control active
18a
& Power limitation active
J9 Power Limiter1) Version VT 5041-3X/3...

Collective fault
1 F
Actual valve value v-act
J1 Compatible with
fault
KB-TP VT 5041-2X: J1 = OFF
Primary
KB-TS
Secondary
1 2a
1 Fault signal = HIGH
swa-act
Actual swivel angle
KB-IW9
value fault
2c
+15 V US Fault signal = LOW
+15V <10 V
U1+U2 unbal Error1)

-15V > 2V
Diagnosis LEDs on printed circuit board

unbal Internal voltage supply
unbalanced
1) LED indicator lamps on the front panel

Alphabetical index
18 Alphabetical index
A Flushing 61
Functional description 16
Abbreviations 8
Functional test 71
Activation sequence 37
Actual pressue value adjustment 68
Actual values 32 G
Actuating system supply 17 Gain of pressure controller 64
Ambient conditions 27 General instructions 10
Ambient temperature 27 General notes 14
Generation of noise 29
B
Basic operating modes 19 H
Bleeding 72 Hydraulic fluids
Brief regenerative operation 23 selection 27
Hydraulic fluid supply
C testing 61
Cabling 53
Care 74 I
Case drain compensation 33, 62 Identification of the product 38
Case drain piping 46 Improper use 9
Circulation operation 22 Initial commissioning 60
Cleaning 74 Inspection 74
Command value Inspection schedule 74
for power limit 58 Installation 43
Command values 58 with coupling 48
Commissioning 59 Installation conditions 43
Configuring switches and jumpers 62 Installation drawing 5
Connecting Installation orientation 45
electrically 52 Installation positions 44
hydraulically 49 Installing 47
Continuous regenerative operation 22 Intended use 9
Control electronics Internal pilot oil supply 25
functions 30
Controller structure 19
Conversion 79 K
Coupling 48 Keyed shaft 30
D L
Data sheet 5 Lifting gear 39
Decommissioning 78
Delivery contents 15 M
Demounting 78
Device description 16 Maintenance 74, 75
Dimensioning 26 Maintenance intervals 74
notes 26 Malfunction table 85
Dimensions 39 Master/slave operation 34
Direction of rotation 47 changing over 36
Disposal 79 Maximum operating pressure 25
Measuring sockets 32
Minimum operating pressure 25
E
Enable 30 N
Environmental protection 79
Extension 79 Nameplate 38
External pilot oil supply 26 Noise level 28
F O
Filling 60 Oil-immersed applications 27
Filtration 28 Open circuit 16
Flange pattern 50 Operating pressure limits 25
Alphabetical index
Operating viscosity 27 Setting a constant power limitation 71

Operation 73 Shaft variant 29
Order confirmation 5 Signal adjustment of actual pressure
value 62
Solenoid
P connecting 58
Performance description 16 Spare parts 76
Personal protective equipment 13 Special operating modes 21
Personnel qualifications 10 Splined shaft 30
Pilot oil 25 Spool variant 30
external 25 Stand-by operation 22
internal 25 Starting up at zero pressure 21
Pilot oil supply Storage 39
internal 25 Storing 41
Piping 44, 45 Switch TD 31
Power limit Swivel angle 100 %
external provision 71 setting 70
Power limitation 21, 33 Swivel angle adjustment 19
adjusting 71 Swivel angle control 20
Pre-compression volume 17 Swivel angle sensing
Pre-load valve 25 checking 70
bleeding 67 Swivel angle sensor
Preparation 47 connecting 57
Pressure command value adjustment Symbols 7
68
Pressure control 21, 69
closed-loop 21 T
Pressure controller Technical data 89
gain 70 Temperature range 27
OFF 31 Testing the hydraulic fluid supply 61
Pressure controller OFF 63 Tightening torques 51
Pressure transducers Tools required 78
mounting orientation 54 Transport 39
place of installation 54 Transporting with lifting gear 39
selection 54 Troubleshooting 80
Product description 16 Type of control
Pulsation damper 29 signaling 31
Q U
Qualifications 10 Unpacking 43
R V
Recommissioning after standstill 72 Valve command value monitoring 63
Regenerative operation 22 Valve position transducer
Related documents 5 connecting 56
Repair 75 Valve shutdown in the event of a fault
Replacement 78 63
Replacement of components 76 Valve zero point
Pilot valve 77 checking and correcting 66
Pre-load valve 77 Viscosity limits 27
Swivel angle sensor IW9 76 Volume adjustment 69
swivel angle sensor IW9-LIN-1X
76
W
Ring screw 40
Routing of lines 50 Warranty 49
notes 50 Weights 39
Running-in phase 72
Z
S Zero stroke 31
Safety instructions 9 Zero stroke operation 22
Seal kits 77 Zero stroke pressure 19
Section 16
Bosch Rexroth AG
Hydraulics
Zum Eisengieer 1
97814 Lohr a. Main, Germany
Phone +49 (0) 93 52/18-0
documentation@boschrexroth.de
www.boschrexroth.com
Printed in Germany
RE 30011-B/05.12
Pressure and flow control system RE 30012-B/09.10
Ersetzt: 08.10
SYDFEE series 2X, 3X English
SYHDFEE, series 1X
Operating instructions
SYDFEE, series 2X SYDFEE, series 3X SYHDFEE, series 1X
Valid for the following types:

Pressure/flow control system
Type SYHDFEE
Type SYDFEE
The data specified above only serve to describe
the product. No statements concerning a certain
condition or suitability for a certain application can
be derived from our information. The information
given does not release the user from the obligation
of own judgment and verification. It must be
remembered that our products are subject to a
natural process of wear and aging.
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. The delivered product may, therefore, differ
from the product which is pictured.
The original operating instructions were created in

the German language.
RE 30012-B/09.10 | SYDFEE series 2X, 3X, SYHDFEE series 1X Bosch Rexroth AG 3/80
Contents
Content
1 About this document ...................................................................................... 5
1.1 Related documents ................................................................................... 5
1.2 Abbreviations used ................................................................................... 6
2 General safety instructions ........................................................................... 7
2.1 Intended use ............................................................................................. 7
2.2 Improper use ............................................................................................. 7
2.3 Personnel qualifications ............................................................................ 7
2.4 Safety instructions in this document ......................................................... 8
2.5 Adhere to the following instructions .......................................................... 8
2.6 Operators obligations ............................................................................. 10
3 Delivery contents .......................................................................................... 11
4 Product description ...................................................................................... 12
4.1 Performance description ......................................................................... 12
4.2 Device description................................................................................... 12
4.3 Controller structure and basic operating modes ..................................... 15
4.4 Special operating modes ........................................................................ 17
4.5 Operating pressure limits ........................................................................ 20
4.6 Ambient conditions.................................................................................. 22
4.7 Notes on the selection of hydraulic fluids................................................ 23
4.8 Noise level .............................................................................................. 24
4.9 Shaft variant ............................................................................................ 25
4.10 Spool variant of the VT-DFPE-x-2X pilot valve ....................................... 26
4.11 Order options for the closed-loop control electronics.............................. 26
4.12 Master/slave operation............................................................................ 28
4.13 Identification of the product ..................................................................... 31
5 Transport and storage .................................................................................. 32
5.1 Transporting the SY(H)DFEE control system ......................................... 32
5.2 Storing the SY(H)DFEE control system .................................................. 34
6 Installation ..................................................................................................... 36
6.1 Unpacking ............................................................................................... 36
6.2 Installation conditions.............................................................................. 36
6.3 Installation positions and piping of SY(H)DFEE systems ....................... 37
6.4 Installing the SY(H)DFEE control system ............................................... 40
6.5 Connecting the SY(H)DFEE control system hydraulically ...................... 43
6.6 Connecting the SY(H)DFEE control system electrically ......................... 46
7 Commissioning ............................................................................................. 51
7.1 First commissioning ................................................................................ 52
7.2 Recommissioning after standstill ............................................................ 60
7.3 Running-in phase .................................................................................... 61
8 Operation ....................................................................................................... 61
9 Maintenance and repair ................................................................................ 62
9.1 Cleaning and care ................................................................................... 62
9.2 Inspection................................................................................................ 62
9.3 Maintenance ........................................................................................... 63
9.4 Repair ..................................................................................................... 63
9.5 Spare parts ............................................................................................. 63
10 Decommissioning ......................................................................................... 67
11 Demounting and replacement ..................................................................... 67
11.1 Required tools ......................................................................................... 67
11.2 Preparing demounting............................................................................. 67
11.3 Demounting the SY(HDFEE control system ........................................... 67
11.4 Preparing the components for storage or further use ............................. 68
12 Disposal ......................................................................................................... 68
12.1 Environmental protection ........................................................................ 68
12.2 Return to Bosch Rexroth......................................................................... 68
4/80 Bosch Rexroth AG SYDFEE series 2X, 3X, SYHDFEE series 1X | RE 30012-B/09.10
12.3 Packaging ............................................................................................... 68

12.4 Materials used......................................................................................... 69
12.5 Recycling ................................................................................................ 69
13 Extension and conversion ........................................................................... 69
14 Troubleshooting ........................................................................................... 70
14.1 How to proceed for troubleshooting ........................................................ 70
14.2 Malfunction table ..................................................................................... 71
15 Technical data ............................................................................................... 75
16 Annex ............................................................................................................. 76
16.1 Address directory .................................................................................... 76
16.2 Block circuit diagram ............................................................................... 77
17 Alphabetical index ........................................................................................ 78
About this document
1 About this document

These instructions contain important information on the safe and appropriate
assembly, transport, commissioning, maintenance, disassembly and simple
troubleshooting of the pressure and flow control systems SYDFEE series 2X, 3X
and SYHDFEE series 1X.
f Read these instructions completely, especially chapter 2 General safety
instructions on page 7, before working with the SY(H)DFEE control system.
1.1 Related documents

The SY(H)DFEE control system is a system component. Also observe the
instructions with regard to the other system components.
Further information on the SY(H)DFEE pressure and flow control system, its
installation and operation can be found in the Rexroth documents listed in the
following table.
Table 1: Related documents

Documentation Contents
Order confirmation Contains the preset technical data of your SY(H)DFEE
pressure/flow control system
Operating instructions General operating instructions, which contain notes on the
RE 90300-B installation of axial piston pumps
Installation drawing Contains the outer dimensions, all ports and connections and
the hydraulic circuit diagram for your SY(H)DFEE pressure/
flow control system
Data sheet RE 30030 Contains the technical data and description of the SYDFEE
2X control system
Data sheet RE 30630 Contains the technical data and description of the SYDFEE-
3X control system
Data sheet RE 30035 Contains the technical data and description of the SYHDFEE
control system
Data sheet RE 92711 Contains the technical data and description of the
A10VSO...18...140 variable displacement pump, series 31
A10VSO...28...180 variable displacement pump, series 32
Data sheet RE 92050 Contains the permissible technical data for the A4VSO axial
piston variable displacement pump, series 10, 11 and 30
Data sheet RE 92053 Contains the permissible technical data for the A4VSO axial
piston variable displacement pump for operation with HFC
hydraulic fluids
Data sheet RE 90223 Contains additional information on the use of Rexroth axial
piston units with HFC hydraulic fluids
Data sheet RE 90220 Describes the requirements for an environmentally acceptable
hydraulic fluid for operation with Rexroth axial piston units and
assists you in selecting a hydraulic fluid for your system
SYDZ0001-1X pre-load valve
VT-DFPEx-x-2X pilot valve
VT-SWA-1-1-X rotary angle sensor for SYDFEE
VT-SWA-LIN swivel angle sensor for SYHDFEE
Data sheet RE 29933 Contains the technical data and description of HM12/HM13-
1X pressure transducers
About this document
Documentation Contents
Data sheet RE 30266 Contains the technical data and description of the HM16-1X
pressure transducer
Data sheet RE 30269 Contains the technical data and description of the HM17-1X
pressure transducer
Data sheet RE 07900 Describes the installation, commissioning and maintenance of
hydraulic systems
Data sheet RE 30030-U Declaration on environmental compatibility
Also observe the generally applicable, legal or otherwise binding regulations of

the European and national legislation and the rules for the prevention of accidents
and for environmental protection applicable in your country.
1.2 Abbreviations used

As umbrella term for the pressure/flow control systems SYDFEE and SYHDFEE
the designation SY(H)DFEE will be used in the following.
Table 2: Abbreviations
Abbreviation Meaning
A/F Width across flats
EMC Electromagnetic compatibility
NG Nenngre (size)
p Pressure (symbol)
pact Actual pressure value
pcomm Pressure command value
pDiff Control difference between pressure command value and
actual pressure value
PE Protective earth
PT Pressure transducer
SWA Swivel angle
SWAact Actual swivel angle value
SWAcomm Swivel angle command value
SYDFEE-2X Pressure/flow control system, series 2X
SYDFEE-3X Pressure/flow control system, series 3X
SY(H)DFEE Pressure/flow control system, analog on-board electronics
SYHDFEE-1X Pressure/flow control system, high pressure, series 1X
RE Rexroth document in the English language
UB Supply voltage
VT-DFPE Pilot valve with integrated analog electronics
VT-SWA Swivel angle sensor VT-SWA for control system SY(H)DFEE
General safety instructions
2 General safety instructions

The SY(H)DFEE control system has been manufactured according to the generally
accepted rules of current technology. There is, however, still a risk of personal
injury or damage to equipment if the following general safety instructions and the
warnings before the steps contained in these instructions are not complied with.
f Read these instructions completely and thoroughly before working with the
SY(H)DFEE control system.
f Keep these instructions in a location where they are accessible to all users at all
times.
f Always include the operating instructions when you pass the SY(H)DFEE
control system on to third parties.
2.1 Intended use

The pressure/flow control system is intended exclusively for being integrated in a
machine or installation or for being assembled with other components to form a
machine or system. The product may be commissioned only if its integrated in the
machine/system for which it is designed.
The pressure/flow control system is intended for the electrohydraulic control of
pressure and swivel angle of an axial piston variable displacement pump.
f Observe the technical data, operating conditions and performance limits as
specified in the data sheet and order confirmation.
The SY(H)DFEE control system is technical equipment, which is not intended for
private use.
Intended use includes having read and understood these instructions, especially
Chapter 2 General safety instructions.
The operation of the SY(H)DFEE control system is only permitted when national
EMC regulations are complied with for the application at hand. If required, notes
on the installation in accordance with EMC regulations can be found in EMC test
documentation of Bosch Rexroth (see RE 30030-U). The manufacturer of the
system or machine is responsible for the adherence to limit values stipulated in
national regulations.
European countries: EC Directive 2004/108/EC (EMC Directive)
USA: See National Electrical Code (NEC), National Electrical Manufacturers
Association (NEMA) as well as regional construction regulations.
2.2 Improper use

The SY(H)DFEE control system must not be used in a potentially explosive
atmosphere.
Any use of the SY(H)DFEE control system other than described in Chapter
2.1 Intended use is considered as improper.
2.3 Personnel qualifications

Assembly, commissioning and operation, disassembly, maintenance and repair
require basic mechanical, hydraulic and electrical knowledge, as well as knowledge of
the appropriate technical terms. For transporting and handling the product, additional
knowledge is necessary with regard to working with a crane and the corresponding
attachment equipment. In order to ensure operating safety, these activities may
therefore only be carried out by qualified personnel or an instructed person under the
direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute
the appropriate safety measures due to their professional training, knowledge and
experience, as well as their understanding of the relevant conditions pertaining to the
work to be done. Qualified personnel must observe the rules relevant to the subject
area.
2.4 Safety instructions in this document

In this manual, there are safety instructions before the steps whenever there is a
risk of personal injury or damage to equipment. The measures described to avoid
these hazards must be observed.
Safety instructions are set out as follows:
SIGNAL WORD! Type of danger!

Consequences
f Precautions
Warning sign: (warning triangle): draws attention to the risk

Signal word: identifies the degree of hazard
Type of risk: identifies the type or source of the hazard
Consequences: describes what occurs when the safety instructions are not
complied with
Precautions: states how the hazard can be avoided.
The signal words have the following meaning:

Signal word Application
DANGER! Indicates an imminently hazardous situation which, if not
avoided, will certainly result in death or serious injury.
WARNING! Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.
CAUTION! Indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injury or damage to
equipment.
If this information is disregarded, the operating procedure may

be impaired.
2.5 Adhere to the following instructions
2.5.1 General instructions

The control system SY(H)DFEE itself does not include safety functions for
personnel safety and is no safety-relevant component. Safety functions for
personnel safety must therefore be provided at a higher level on the system
side.
Observe the regulations for accident prevention and environmental protection

for the country where the product is used and at the workplace.
Only use Rexroth SY(H)DFEE control systems in good technical order and
condition.
Inspect the product for obvious defects.
Should leakage occur or even oil jets be emitted during operation, shut the
system down immediately and replace the damaged commponent.
Do not modify or retrofit the SY(H)DFEE control system, except as described in
Chapter 13 Extensions and conversion on page 69.
Only use the product within the performance range provided in the technical
data.
Persons who assemble, commission, operate, disassemble or maintain Rexroth
products must not consume any alcohol, drugs or pharmaceuticals that may
affect their ability to respond.
The warranty only applies to the delivered configuration.
The warranty is rendered void if the product is incorrectly assembled,
commissioned or operated, as well as if not used as intended and/or handled
improperly.
Do not expose the product to any mechanical loads under any circumstances.
Never use the product as a handle or step. Do not place/lay any objects on it.
The noise emission of SY(H)DFEE control systems depends on speed,
operating pressure and installation conditions. The sound pressure level may
rise above 70 dBA under normal operating conditions. This can cause hearing
damage.
Always wear hearing protection while working in the vicinity of the
SY(H)DFEE control system while it is in operation.
The SY(H)DFEE control system heats up considerably during operation. The
pilot valve of the SY(H)DFEE control system gets so hot during operation that
you may burn yourself:
Allow the SY(H)DFEE control system to cool down sufficiently before
touching it.
Wear heat-resistant protective clothing, e.g. gloves
Hydraulic oil is flammable. Keep the control system away from fire and sources
of heat end ensure sufficient venting.
2.5.2 During transport

Make certain that the lifting gear has adequate lifting capacity. The weight can
be found in Chapter 5 Transport and storage on page 32.
2.5.3 During installation

Before installing the product, make sure that all fluids have been completely
removed from the SY(H)DFEE control system to prevent mixing with the
hydraulic fluid used in the hydraulic system.
Make sure the relevant system component is not under pressure or voltage
before assembling the product or when connecting and disconnecting plug-in
connectors. Protect the system against being switched on.
Observe installation notes as well as the strength classes and tightening
torques specified for screws.
Lay cables and lines so that they cannot be damaged and no one can trip over
them.
Before commissioning, make sure that all hydraulic connections are tight and
that all the connection seals and plugs are installed correctly to ensure that they
are leakproof, and fluids and contaminants are prevented from penetrating the
product.
When installing the product, provide for absolute cleanliness in order to prevent
contaminants such as welding beads or metal cuttings from getting into the
hydraulic lines and causing product wear or malfunctions.
2.5.4 During commissioning

Let the product acclimate itself for several hours before commissioning,
otherwise water may condense in the housing.
Make sure that all electrical and hydraulic connections are either used or
plugged. Commission the product only when it is installed completely.
2.5.5 During cleaning

Plug all ports and open connections with the appropriate protective equipment
in order to prevent detergents from penetrating the system.
Never use solvents or aggressive detergents. Use only water and, if necessary,
a mild detergent to clean the SY(H)DFEE control system.
Do not use a high-pressure cleaner for cleaning.
2.5.6 During maintenance and repair

Perform the prescribed maintenance work at the intervals specified in the
operating instructions (see Chapter 9.3 Maintenance on page 63).
Make sure that no lines, connections or components are disconnected as long
as the system is under pressure. Protect the system against being switched on.
2.5.7 Disposal
Dispose of the product and the hydraulic fluid in accordance with the currently
applicable national regulations in your country.
2.6 Operators obligations

The operator of the SY(H)DFEE control system from Rexroth must provide
personnel training on a regular basis regarding the following subjects:
Observation and use of the operating instructions and the legal regulations
Intended use and operation of the SY(H)DFEE control system
Observation of the instructions from the factory security offices and of the work
instructions from the operator
Rexroth offers training support for special fields. You can find an overview of
the training contents on the Internet at:
http://www.boschrexroth.de/didactic.
Delivery contents
3 Delivery contents
6
3
3
4
5
1
3
2
Fig. 1: Control system SYDFEE-3X
The following is included in the scope of delivery:

1 control system SY(H)DFEE
When delivered, the following parts are mounted additionally:
Transport protection for drive shaft end for keyed shaft (1)
Protective cover (2) with mounting screws
Plastic plugs/plug screws (3)
Protective cover (NG140) or plastic plug (NG18...100) on
preload valve (4)
Pressure transducer (optional) (5)
The connection flange is closed operationally safe with a

cover (optionally on variant with through-drive) (6).

Fig. 2: Control system SYHDFEE

Product description
4 Product description
4.1 Performance description

The SY(H)DFEE control system is designed and built for the electrohydraulic
control of swivel angle, pressure and power (optional) of an axial piston unit. It is
intended for stationary applications.
Please refer to the data sheet and order confirmation for the technical data,
operating conditions and operating limits of the SY(H)DFEE control system.
4.2 Device description

The SY(H)DFEE control system is based on an axial piston variable displacement
pump of swashplate design for hydrostatic drives in the open circuit. The flow
is proportional to drive speed and displacement. The flow can be steplessly
changed by adjusting the swashplate.
Open circuit With an open circuit, the hydraulic fluid flows from the tank to the variable
displacement pump and is transported from there to the consumer via a
directional valve. From the consumer, the hydraulic fluid flows back to the tank
through the directional valve.
In the regenerative operating mode (Chapter 4.4.1 on page 19) the hydraulic fluid
can also flow from the consumer through the pump to the tank.
4.2.1 Functional description, section of the SY(H)DFEE

The numbers in the following description refer to Fig. 3, 4 and 5 on page 13/14.
The pressure and swivel angle of the A10VSO variable displacement pump
of the SY(H)DFEE control system is controlled using an electrically operated
proportional valve (2). The proportional valve determines the position of the
swashplate (1) by means of the actuating piston (4). The displaced flow is
proportional to the position of the swashplate. The counter-piston (3), which is
preloaded by a spring (5), is permanently pressurized to pump pressure.
With a non-rotating pump and depressurized actuating system, the swashplate is
held by the spring (5) in position +100 %. With a driven pump and a de-energized
proportional solenoid (8) the system swivels 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 on the actuating piston and the spring force (5) is
achieved at a pressure of 8 to 12 bar. This basic position (= zero stroke operation)
is obtained e.g. when the valve electronics is de-energiized.
In contrast to this, a pump with external supply swivels to the negative limit
stop (regnerative operation). See also section Basic positions of swivel angle
adjustment feature on page 14.
The proportional valve is controlled by analog electronics (11), which is integrated

in the valve. This closed-loop control electronics processes all of the control
signals required to operate the A10VSO variable displacement pump under
closed-loop pressure and flow control.
The closed-loop control electronics is provided with a command value input each
for pressure and swivel angle on the central plug (12); for the optional power
limitation, the command value can be adjusted using an internal potentiometer or
be provided via an analog value, depending on the specification in the order. A
pressure transducer can be connected to the central plug (12). Alternatively, with
order option F (actual pressure value input), an HM16 pressure transducer can
be connected using an M12 mating connector (13). This pressure transducer can
Product description
be mounted and connected to port P of the pump or, in the case of control system
SYDFEE with an SYDZ pre-load valve, to port MP1.
A position transducer with integrated electronics (7) fitted to the pump establishes
the actual swivel angle value. The acquired actual values are processed in the
amplifier and compared with the given command values. The minimum value
comparator ensures that automatically only the controller is active that is assigned
to the required working point. Thereby, a system variable (pressure, swivel angle
or [optionally] power) is exactly controlled, the other two values are below the
specified command values. The output signal of the minimum value comparator
becomes the command value for the valve control loop.
The actual value of the valve spool position is sensed using an inductive position
transducer (6). The output value of the valve position controller determines 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.
When the higher-level controllers demand an increase in the swivel angle
(increase in flow), the valve spool (9) must be moved from the central position
(connection of the actuating piston (4) A T) until the swivel angle reaches the
required value. The movement of the valve spool against the force of the spring
(10) is achieved by a corresponding increase in the electrical current through the
proportional solenoid (8).
A reduction of the swivel angle (reduction in flow) is achieved by connecting the
actuating piston (4) from P A.
Actuating system supply The actuating system of the pump can be supplied with pilot oil in three different
ways:
1. Internal, without pre-load valve (only possible for operating pressures
> 12...20 bar, see Chapter 4.5 on page 20)
2. Internal, with pre-load valve (operating pressure 0100 %)
3. External supply via a shuttle valve - automatic changeover between internal/external
via a shuttle valve sandwich plate (see 4.5.1 External pilot oil on page 21)
5 3
8 6
10 PA T
1 4 9
2
12
11
14
13
Fig. 3: Type SYDFEE, series 2X (M12) for HM16, variant F only
Product description

P A T

/VMMIVC

Fig. 4: Type SYDFEE, series 3X
7
11
6 13
8
1 4
12
3 10
5
Fig. 5: Section of SYHDFEE, series 1X
Basic positions of swivel angle The sectional drawings above show the mechanical basic position +100 % of
adjustment feature the pump (depressurized, drive at rest). This corresponds to the maximum swivel
angle of the pump.
Zero stroke pressure: Pressure, which the pump with internal supply generates
for its own supply without activation of the pilot valve. The pressure level is
usually within the range of 8 to 12 bar. This pressure level can only be achieved
when the maximum oil flow, which the pump can deliver, is not exceeded (the
consumer line is closed). The pump with internal supply automatically swivels in
to zero stroke operation after the electric drive was started and when the control
electronics is de-energized, provided that the required pilot pressure can build up
(consumer line is closed).
In contrast to this, the pump with external supply swivels in to the negative limit
stop -100% when the control electronics is de-energized!
Product description
Risk of damage to the pump!

CAUTION!
On systems with external supply, the pump may cavitate.
f To avoid damage to the pump, a pressure relief/anti-cavitation valve must be
provided for systems with external supply. If a fault occurs during operation -
not during start-up - the motor must be switched off.
4.3 Controller structure and basic operating modes

Controller structure The controller structure is illustrated in the figure below
(Pin 8)
actual pressure (pin 10/11) U
p
Power Pressure Valve command value
controller controller
(option)
Power setpoint Minimum
Pressure setpoint (pin 7) Valve
(potentiometer value
controller s
or pin 9) comparator U
Minimum Flow
value controller
comparator
Swivel angle setpoint
s
(pin 5) U
Actual swivel angle (pin 6)
Fig. 6: Controller structure
Basic operating modes Up to three controllers are continuously active in the possible operating modes:
Pressure controller
Power controller (optional)
These controllers alternate automatically and jerk-free through evaluation of

minimum value comparators.
During steady-state operation, one of the above controllers is active. For the other
controllers, the actual value is smaller than the command value.
The following operating modes are available:
4.3.1 Closed-loop swivel angle control

If the axis is to run exclusively in this operating mode, an analog signal within the
range of +10.0 V to UB is assigned to the pressure command value and used to
deactivate the pressure controller (0 ... +10 V 0...100 % swivel angle).
The pressure transducer signal should be short-circuited or deactivated,
because even actual pressure value signals of 8.0 V have an influence on or
reduce the swivel angle output and hence the valve command value (actuating
speed!).
A precondition for this is, however, that the electronics is designed for an
actual pressure input voltage without raised zero point (offset). Otherwise, the
electronics, which is selected for an actual value branch with raised zero point
(e.g. 4...20 mA or 0.5... V), would be in an erroneous state when the pressure
transducer signal is missing.
Product description
+10V to UB 7 pcomm
external
4
u
0V
Reference potential
u
H 10 pact 0 to +10V
11
u
0 to 5V u
L
5 comm:0 (-10V) to +10V
4
u
Reference potential
u
SYD_008
Fig. 7: Circuitry of integrated electronics VT-DFPE...-2X/V for closed-loop swivel angle

control

If the axis is to operate in this mode, an analog signal within the range from
+10.0 V to UB can be assigned to the swivel angle command value and used
to deactivate the swivel angle controller. However, for some applications, it is
advantageous to limit the swivel range of the pump by feedforwarding a suitable
swivel angle command value. However, this command value must be sufficiently
great in order that the pressure controller can swivel out the pump to the required
extent.
WARNING! Risk of personal injury and damage to material!

Excessive pressure can cause the pipes to burst. Parts may fly around and oil
be ejected under high pressure, which can result in serious injury. The electrical
pressure control does not assume a pressure relief function.
f If no pre-load valve is used, install a pressure relief valve, which is set 10 %
higher (recommendation) than the operating pressure.
4.3.3 Power limitation (options B and C)

This version allows optimum matching with the performance limits of the drive
motor.
Due to the relationship of P comm * pact the power controller intervenes with a
reducing/limiting effect (power hyperbola) via the swivel angle command value
branch, if required.
Product description
100
max. flow [%]

power
0
0 100
actual pressure [%]
4.4 Special operating modes

This chapter describes certain applications. In these cases, the basic operating
modes (see Chapter 4.3, page 15) are active.
Starting up at zero pressure For starting up SY(H)DFEE systems, no hydraulic circuit needs to be provided for
the classical start-up at zero pressure.
When small command values for pressure and swivel angle are provided, starting
up under almost no-load conditions is possible.
Circulation operation (by-pass In the case of systems with internal supply and without pre-load valve, hydraulic
filtration, cooling) circulation circuits must be dimensioned so that a minimum pressure between
8...12 bar is obtained, because the pump requires this pressure level in order to
be able to respond to electrical control signals.
Stand-by operation Operating mode of the pump, in which an operating point is statically closed-loop-
controlled with a corresponding command value over a longer period of time.
Observe the notes on permitted pressures in Chapter 4.5.1 Internal/external pilot
oil (page 21).
Zero stroke operation Operating mode of the pump that refers to the smallest, achievable swivel angle
and to which the pump usually changes over when no closed-loop control is active.
Zero stroke operation can be definitely achieved only by means of a minimum
command value feedforward in the closed swivel angle control loop.
The feedforward of 0 bar via the pressure command value branch is not
permitted for actuating systems with external supply. In the case of systems with
internal supply this is problematic only in the case of a step-change from a high
pressure to 0, because undershoots may occur.
The following is valid when the valve electronics is de-energized:
Zero stroke operation for the internally supplied pump
Swiveling out to -100% of the externally supplied pump
Product description
4.4.1 Regenerative operation

Regenerative operation is a special operating mode of the SY(H)DFEE control
system, since in this case the SY(H)DFEE control system is operated as both,
generator and motor.
Continuous regenerative operation We can distinguish between continuous regenerative operation and brief
regenerative operation. In the first case, by this we understand coupling of the
variable displacement pump with a fixed displacement pump. Here, the two pump
displacements are combined and fed to a common consumer.
This operating mode can be utilized in conjunction with a fixed displacement
pump in order to increase the displacement. To achieve zero displacement,
the closed-loop controlled pump must take over the entire flow from the fixed
displacement pump and therefore swivels to the negative swivel angle range
(motor operation). It must be noted here that both pump sizes must be matched
to each other in a way that the controlled pump (in regenerative operation) must
swivel in to max. 70 %. The fixed displacement pump should be mounted to a
through-drive of the SY(H)DFEE control system.
The following pump variants are available for continuous regenerative operation:
0487: Continuous regenerative operation with external supply
0541: Continuous regenerative operation without external supply (for SYDFEE-3X
only)
In the case of pump variants with external supply this operating mode is
somewhat complicated in terms of engineering and commissioning, because a
pump swiveling in too far (e.g. -75 % instead of -70%) causes cavitation.
We therefore recommend master/slave operation as an alternative with two
closed-loop controlled SY(H)DFEE systems or pump variant 0541 for
SYDFEE-3X.
Continuous operation is possible when the given operating limits are adhered
to. However, at a total displacement of zero (that is, at a negative swivel angle
of the SY(H)DFEE pump) and at high pressures, the noise level increases and
efficiency deteriorates.
For pumps with external supply, the use of a pressure relief and anti-cavitation
feature as shown in Fig. 9 is indispensable to prevent the pumps running dry.
pmax 0,2 bar
Pressure relief/anti-
Q1 Q2 max< 0,7 Q1
cavitation valve required in
the case of external supply
Fig. 9: Circuit diagram for continuous regenerative operation

Product description
p[bar]
280
250
200
Control system for continuous

regenerative operation:
SYDFEE 2X oder 3X
150 NG 18...100 with SO 0487 or 0541
NG 140
100
50
Ist [%]
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
0 SYD 01
Fig. 10: Operating limits for series SYDFEE-2X and SYDFEE-3X with special rotary
group for continuous regenerative operation
Brief regenerative operation During brief regenerative operation the variable displacement pump changes over
to motor operation for a limited period of time, e.g. for lowering a load. If the
requirement profile remains within the limits according to Fig. 11, the standard
version of the pump can be used (standard rotary group 0000 or 0479).
p[bar]
280
250
200
Standard rotary group

150
100
50
Ist [%]
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
0 SYD 02
Fig. 11: Operating limits for series SYDFEE-2X and SYDFEE-3X with standard rotary
group for brief regenerative operation
Product description
Regenerative operation for With series SYHDFEE-1X we do not differentiate between brief and continuous
SYHDFEE-1X regenerative operation. The operating limits are shown in Fig. 12, otherwise
observe the notes given on continuous regenerative operation and brief
regenerative operation on the previous pages.
p[bar]
350

280

SYHDFEE
NG 125 - 355
Ist[%]
-100 -90 -80 -70 -60 -50 -40 -30 -20 -10 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100
0 SYD_028
Fig. 12: Operating limits for SYHDFEE
4.5 Operating pressure limits
WARNING! Ejecting parts and fluid jets!

Risk of injury! The electrical pressure control does not assume a pressure relief
function.
f Make sure that the maximum operating pressure is not exceeded.
f If a pre-load valve is installed, you can use its pressure relief function. If no
pre-load valve is provided, install a pressure relief valve in the pressure line,
the pressure setting of which is 10 % (recommended) higher than the operating
pressure. If you do without this valve, the pump can be damaged due to
malfunction.
Maximum operating pressure The maximum operating pressure specified in the data sheet must not be
exceeded.
At a pressure of 250 bar the following restrictions must be observed for
SYDFEE:
The pressure transducer must be located downstream of a pulsation damper

or the high-pressure hose.
When a standard pilot valve spool is used (version A), the pressure
controller P-gain (SO version of VT-DFPE valve) may have to be reduced.
This has an influence on the accuracy and dynamics of the closed pressure
control loop.
Product description
The loop gain can also be reduced by installing a pressure transducer of a

higher pressure rating (e.g. 400 bar).
Minimum operating pressure The minimum operating pressure depends on the pilot oil supply and is explained
in more detail in the following chapters.
4.5.1 Internal/external pilot oil

Internal pilot oil supply If the operating pressures of the application are always > 20 bar, the version with
internal pilot oil supply should be selected, because cavitation due to too small
command values is impossible with this version.
Operation is also possible at pressures higher than approximately 12 bar, but
dynamics is restricted within the range below 20 bar.
This minimum (pilot) pressure level ensures that the pump can respond to the
electrical swivel signal at any time. When the consumer line is blocked, the
smallest achievable swivel angle is zero stroke.
For applications, in which smaller operating pressures occur or are to be
controlled, a pre-load valve (SYDZ for SYDFEE) can be used. For this solution,
the minimum pressure is 1 bar.
Pre-load valve The advantage of the pre-load valve is that the pilot oil pressure of the pump
cannot fall below the value preset on the pre-load valve and that pressures
10 bar on the output side can be continuously controlled.
Being equipped with a pre-load valve the pump cannot permanently swivel back
over zero irrespective of electrical actuating signals or any control errors. This
is not valid for applications, in which, for example, a suspended load can cause
operating pressures 12 bar. In such cases the pump can also be used in motor
operation (for lowering the load). A check valve integrated in the pre-load valve
permits, within certain limits, a reversal of the direction of oil flow.
When using pump combinations
NG45 with 45/28/18 or

NG28 with 28/18 or
NG18 with 18
in conjunction with the SYDZ pre-load valve on the main pump, there is a
mechanical conflict between port P1 of the pre-load and the position transducer
housing of the rear pump fitted. For this reason, we suggest that the main pump
of the above combinations be equipped with an SAE flange plate (NG28) or
1 (NG45) having a height of h = 45 mm. The construction height of the pump
assembly therefore changes by dimension h.
External pilot oil supply Also here, the minimum pressure is 1 bar. With external pilot oil supply (0479
for external supply or 0487 for external supply plus regenerative operation for
SYDFEE; 0576 for SYHDFEE) pressures 10 bar are only permitted briefly (max.
10 minutes).
An additionally built-on sandwich plate with shuttle valve automatically switches
the pilot oil supply between the internal or external pilot oil source, with always the
higher pressure level being selected.
A pump with external pilot oil supply can be recognized by
the sandwich plate mounted below the pilot valve and
the hose routed around the pump case.
On the SYHDFEE control system, the Z-port is located next to the swivel angle
transducer.
Product description
With external pilot oil supply, the actuating system of the SY(H)DFEE pump works
independently of the actual high-pressure circuit, thus allowing an adjustment also
below an operating pressure of 12 bar within the range of 100 % (change in the
direction of displacement!).
When the control electronics is deactivated, the pump swivels to position
-100 % (motor operation) in an uncontrolled manner. This can lead to
cavitation and damage to the pump.
For this reason, special features are to be provided such as a pressure relief and
anti-cavitation valve and actual swivel angle value monitoring.
The pressure relief and anti-cavitation valve diminishes the risk of the pumps
running dry, the effects of which result in a reduction in the pumps service life.
The actual swivel angle value monitor could, for example, switch off the entire
drive or selectively shut off the pilot oil flow.
The following is valid for the actuating pressure:
Pilot oil pressure minimum operating pressure + 30 bar
Recommendation: Absolute pilot oil pressure 20 bar
Further notes on the operation with external supply:
In the case of external supply, the pump does not swivel to zero stroke when
the pilot valve is de-energized.
Command values for pressure and flow must always be greater than 1 bar or
5 %, because there is no exact zero pressure or zero swivel angle due to
drift or inaccurate settings. For this reason, selections equal to zero or slightly
greater can lead to cavitation in unfavorable cases.
In order to ensure sufficient lubrication for the pump system at all times, the
actual pressure value must not be less than 10 bar for longer than 10 minutes!
Notes on dimensioning At a pilot oil pressure of 20 bar the brief pilot oil requirement during swiveling is
ca.17 l/min; at 50 bar (SYHDFEE) it is ca. 25 l/min. In practice, this amount of pilot
oil is needed only, if the operating pressure is less than 20 bar during the entire
swiveling process and thus the entire pilot oil demand must be supplied by the
external source.
In the steady-state, balanced condition, the pilot oil requirement is less than
1 l/min.
Experience has shown that, depending on the operating pressure and swiveling
frequency, the actual pilot oil demand is in the order of 5...15 l/min. In the case
of external supply, a smaller pump size may be selected if an accumulator is
provided.
4.6 Ambient conditions
4.6.1 Oil-immersed applications

Only the SY(H)DFE1 control system is suitable for oil-immersed applications.
SY(H)DFEx systems with integrated electronics must not be immersed.
4.6.2 Ambient temperature

The permissible maximum ambient temperature for the SY(H)DFEE control
systems is 60 C.
Product description
We recommend the installation within a ventilated area with moved ambient

air, e.g. in the air flow of an electric motor.
This is valid in particular in view of the place of installation of the integrated
electronics.
4.7 Notes on the selection of hydraulic fluids

General
The SYDFEE control system is designed for operation with hydraulic fluids in
accordance with DIN 51 524 (HL/HLP). The use of HFC is permitted only for
SYHDFEE with option F.
Operating viscosity We recommend that the operating viscosity (at operating temperature) be within
the following range, which is optimum in terms of efficiency and service life:
opt = optimum operating viscosity 16...36 mm/s.
This range is referred to the tank temperature in the open circuit.
Viscosity limits The following values are valid for limiting operating conditions:
min = 10 mm/s
Briefly, at max. permissible leakage oil temperature of 90 C
max = 1000 mm/s
Briefly, during cold start
Temperature range The temperature of the hydraulic fluids lies between the following values: (cf.
selection diagram)
tmin = -20 C
tmax = 70 C
Selection diagram for the hydraulic

fluid 2500-40 -20 0 20 40 60 80 100
1600 1600
1000
600
400
200
V 6
V
V 3
V 46
V 22
G 8
G
G 2
G
G
10
100
0
60
40
Viscosity range
36
opt.
20
16
10
5 5
-40 -25 -10 0 10 30 50 70 90
Temperature range t in C
tmin = -20 C tmax = +70 C
Hydraulic fluid temperature range
Product description
Notes on the selection

In order to be able to select the correct hydraulic fluid, the operating
temperature in the tank (open circuit) in relation to the ambient temperature
must be known.
The hydraulic fluid should be selected so that within the operating temperature
range, the operating viscosity is within the optimal range (opt). This range is
shown as shaded area in the selection diagram.
We recommend that you select the next higher viscosity class.
Example:
At an ambient temperature of X C, the resulting temperature in the tank is
60 C. Within the optimum operating viscosity range (opt; grey-shaded area) this
corresponds to viscosity classes VG 46 and VG 68. You should select: VG 68.
The case drain oil temperature, which is subject to the influence of pressure
and pump revving speed, is always higher than the tank temperature.
However, the temperature must not exceed 90 C at any point in the system.
If the conditions described above cannot be complied with due to extreme
operating parameters or high ambient temperatures, please consult us.
Filtration of the hydraulic fluid The finer the filtration of the hydraulic fluid, the better is the achieved cleanliness
class, which, in turn, prolongs the service life of the SY(H)DFEE control system.
To ensure operational reliability of the SY(H)DFEE control system, at least
cleanliness class 18/16/13 according to ISO 4406 (for particle sizes 4/6/14 m) is
required.
HFC fluids
The use of HFC fluids is permitted only for SYHDFEE control systems with
option F. For applications with HFC fluids, it must be noted that, due to the
reduced lubrication ability of HFC fluids, the service life of the SYHDFEE
control system is reduced when compared with the standard application.
For applications with HFC fluids, the 4-groove spool must be used for the pilot
valve. The spool is specified by C in the ordering code of the SYHDFEE
control system.
For commissioning pump systems that are operated with HFC fluids, please
read the relevant commissioning instructions (among others, RE 92053),
which are available as separate documents.
4.8 Noise level

For design-inherent reasons, when compared with vane pumps, axial piston
pumps generate greater changes in flows and thus pressure pulsations. Apart
from the propagation of air and structure-borne noise, this can have an influence
on fluid-borne noise. In the end, these factors together result in the general
perception of noise.
Noise often induces vibration on other components, which, in turn, also generate
noise. For example, on check valves, which may be installed, the integrated
springs must be adapted to the conditions of the systems, if this is a cause of
excitations leading to the generation of noise.
The details given for the noise pressure level in the technical documentation refer
to measurements taken in an anechoic room. Influences of the surroundings such
as place of installation, general mechanical concept, piping, etc. are not taken into
account.
Product description
4.8.1 Generation of noise in the power unit

Noise is composed of different elements. The total result of noise is influenced
not only by air-borne noise, but also by structure- and fluid-borne noise.
As a result of unfavorable installation and piping conditions, the noise pressure
level of the complete system can be 5 to 10 dB(A) higher than the value of the
pump alone.
Noise can be reduced by taking, for example, the following measures:
Low-noise tank
Damping ring between pump and pump mounting bracket
Flexible pipe conduit
Anti-vibration rails under the motor
Installation of the pump at a sufficient distance to the tank wall
4.8.2 Pulsation damper

For some special applications, wer recommend the use of a pulsation damper.
Due to the reduction of typical pump pressure pulsation, this has a positive effect
on the noise level of the hydraulic system as a whole.
Further information can be found in data sheet RE 50142.
4.9 Shaft variant

The SY(H)DFEE control system is available with keyed or splined shafts. When
compared with the keyed shaft, the splined shaft is not only advantageous with
regard to its degrees of freedom during assembly and operation, but also due to
its increased torque load carrying capacity and its stability under changing loads.
This increased torque load carrying capacity is useful in particular when pump
combinations are to be installed. In the case of multiple pumps, all built-on units
are fitted with splined shafts.
In view of the dynamic load carrying capacity and standardization, we recommend
the use of standard types with splined shafts. This offers advantages with regard
to availability and future spare parts requirements.
When a splined shaft is selected, a clamp coupling must be used for the
mechanical connection to the electric motor. Otherwise, frictional corrosion may
occur that leads to damage to the pump.
Notes on the permissible maximum transmission of torques can be found in the
data sheet.
Keyed shaft
Due to the advantages of the splined shaft, keyed shafts are not recommended
for new applications. The keyed shaft is no longer used for applications with
through-drive.
If a single pump is to be used later as end pump in a multiple-pump system, a
splined shaft must be selected.
Product description
Splined shaft
Splined shaft profiles depend on the size (NG) of the pump. Two different splined
shaft profiles are available in conjunction with SY(H)DFEx :
S-profile for NG18, NG100 and NG140
R-profile for NG28 ... 71
When compared with the S-profile, the R-profile offers further improved
properties with regard to the torque carrying capacity of the shaft. This version
represents the optimum for a wide variety of applications.
4.10 Spool variant of the VT-DFPE-x-2X pilot valve

The standard spool according to the ordering code is spool type A (360 spool).
Especially for press applications (280 bar) type C (4-groove spool) has proven in
practice in conjunction with the SYDFEE control system.
The 4-groove spool of type C is also allocated to SYHDFEE as standard for
applications using HFC media.
4.11 Order options for the closed-loop control

electronics
The control electronics of analog SY(H)DFEE systems are designed so that only
the controller parameters for pressure can be variably adjusted. For closed-loop
swivel angle control a fixed parameter setting is provided for all sizes.
The following variants of the control electronics can be ordered optionally:
Ordering code:
A Standard, without power limitation, pressure controller with changeover
feature
Pin 9 = switching input changeover of controller setting
B With power limitation using the integrated potentiometer
Pin 9 = switching output power limitation reached
C Power limitation with variable selection
Pin 9 = analog input power limit 0...10 V
D Pressure controller that can be switched off (High signal)
Pin 9 = switching input deactivate pressure controller
Pin 9 = Switch TD
4.11.1 Pressure controller with changeover feature

The PD-controller can be optimally adjusted to the properties of the system by
means of the rotary switch provided for this purpose.
You can select from various PD-controller settings in dependence on the oil
volume. Here, the P-component is fixed, whereas the D-component can be varied
from 0 to F by means of rotary coding switch S1.
If you select variant A = without power limitation, a further controller
parameterization, which is assigned to the relevant position of the rotary switch
(switch TD), can be called up via the existing switching input.
Product description
4.11.2 Case drain oil compensation

As the operating pressure rises, the amount of internal leakage of the SY(H)DFEE
control system increases.
For this reason, a certain external swivel angle command value is applied in order
to exercise a pressure-dependent influence on the pumps displacement:
The displacement of the pump decreases at higher pressures.
The standard versions of the various control electronics therefore comprise an
automatic case drain oil compensation feature that constantly adds a certain
percentage of the actual pressure value as correction factor to the swivel angle
command value. This, however, results in differences between the externally
provided swivel angle command value and the actual swivel angle signal when
this compensation feature cuts in.
For integral analog electronics, the deactivation of the compensation feature can
be ordered as an optional extra.
In certain applications and with integrated, connected pressure transducer,
pressure fluctuations, which occur during displacement operation (swivel angle
control), can have an unfavorable effect on the swivel angle control when the
corrective feature described above becomes active. In this case, the swivel angle
control can be stabilized by reducing or deactivating case drain oil compensation.
Reasons for pressure fluctuations can be the following:
Process- or material-related
Hydraulic motors with a small number of pistons
Lifting cylinders with a low natural frequency
Superimposed, closed position or velocity control loop
4.11.3 Power limitation

In the case of electronic variants with extra function (feature 12 in the type
code) Power limitation adjustable on the pilot valve, a limiting value can be set
by means of a potentiometer. If the optional function power limitation via analog
input is selected, the limiting value is provided externally.
100
max. flow [%]
power
0
0 100
actual pressure [%]
When the power limiter cuts in, the operating variables (pressure and flow) adjust
automatically according to the curve path of the set power hyperbola.
Product description
The adjustment of the power limitation is described in Chapter 7 Commissioning

on page 51.
4.12 Master/slave operation

Circuitry of SY(H)DFEE for master/slave operation
UB
0V
1 UB 1 UB
2 L0 2 L0
4 M0 4 M0
SWAcomm (I) 5 SWAcomm SWAact 6 5 SWAcomm
pcomm (I) 7 pcomm 7 pcomm
10 pact - high 10 pact - high

P
U 11 pact - low 11 pact - low
Master Slave
Fig. 14: Circuitry of SY(H)DFEE for master/slave operation
Theoretically, an optional number of SY(H)DFEE control systems can be

hydraulically coupled to achieve greater flows.
In this case, it is just required to determine a master pump to which the pressure
transducer, if provided, has to be connected.
The master controls both, pressure and swivel angle, in accordance with the
externally provided command values and passes its actual swivel value (SWAact)
on to the slave pumps as swivel angle command value (SWAcomm). This ensures
smooth and synchronous swiveling of the pumps.
Consequently, the slave pumps operate only under swivel angle control, which is
the reason why in this operating mode no pressure transducer signal may be fed
to their control electronics.
Product description
Circuitry of SY(H)DFEE with electronics variant A, B, C

UB
0V
1 UB 1 UB
2 L0 Master/slave 2 L0
operation ON
4 M0 4 M0
comm (I) 5 SWAcomm 5 SWAcomm

SWAcomm (II)
SWAact 6
0V
10 pact - high 10 pact - high
P
U P
11 pact - low
U 11 pact - low
pcomm (I) 7 pcomm pcomm (II) 7 pcomm
Master Slave
Fig. 15: Circuitry of SY(H)DFEE for master/slave and individual operation
Circuitry of SY(H)DFEE with electronics variant D

UB
L0
Master/slave operation ON
1 UB 1 UB
2 L0 2 L0
4 M0 4 M0
SWAcomm (I) 9 Pressure

5 SWAcomm
controller OFF
SWAact 6
pcomm (I) 7 pcomm 5 SWAcomm
SWAcomm (II)
10 pact - high pcomm (II) 7 pcomm

P
U 11 pact - low 10 pact - high
P
Master U 11 pact - low
Slave
Fig. 16: Circuitry of SY(H)DFEE for master/slave operation and individual operation
Notes:
Select the electronics for the slave axis in the variant pressure transducer with
voltage input 0...10 V (SY(H)DFEE/...V...).
The connection for the position transducer of the pumps is not drawn.
The coupling element (relay, analog switch) can be optionally installed to
control both pumps independently of one another. With the proposal shown
here, both, swivel angle and pressure control, are possible with the slave pump.
For the master/slave operating mode, the signal pcomm(II) must be set to
maximum (+10 V...UB).
If closed-loop pressure control is to be possible also in the master/slave
Product description

possible, a separate pressure transducer is required also for the slave.
If the signal branch of the pressure transducer of the slave axis is not provided
with a specific circuitry, its pressure controller could intervene into the swivel
angle control in an undesirable manner, when the actual pressure value
pact(II) reaches values in the order of ca. 80 % or higher of the command value
pcomm(II). Care must be taken that the D controller parameter on the slave is
not set higher than on the master. When electronics variant D is used, the
pressure controller can be switched off via a switching input (pin 9). As a result,
only the swivel angle controller is active - independently of pcomm or pact (with
D, no control parameter changeover is provided).
Changing over to master/slave operation
Starting point 0 V reference potentials of the PLC/command value source and M0/L0 of the
SYDFEE electronics must be connected.
Operate both pumps until they reach the point shortly before they change
over to closed-loop pressure control (low, identical pressure level) and are still
hydraulically uncoupled from each other. Approximately identical actual swivel
angle values would be optimal. Set the flow command value to a low value (e.g.
10 %).
When a pre-load valve is used, it should preferably be installed on the master
pump.
Changing over to master/slave At low operating pressures, the flow command value, which has been previously
operation provided by the control, is withdrawn from the slave pump via a changeover
contact suitable for small signal voltages (or, alternatively, a wear-free analog
switch), and the actual swivel angle value provided by the SY(H)DFEn electronics
of the master pump is fed forward.
The pressure command value of the slave pump is set to 100 % (if required, via
a second changeover contact or by means of software) in order that closed-loop
pressure control of this unit is quasi switched off. With electronics D: High signal
at pin 9.
Now, the hydraulic short-circuit valve (connection of the previously separated
pressure circuits) can be activated. A delayed activation of this valve may have to
be adjusted depending on whether this would improve the system characteristics
in the changeover process.
Deactivating master/slave operation In the master/slave operating mode it is also useful that the control keeps the two
swivel angle command values for the master and the slave pump synchronized in
order that striking differences in the signal level are prevented when the swivel
angle command value source for the slave pump is changed (from actual swivel
angle value of the master pump back to the control output).
The pressure command value of the slave pump should be set to the same level
as that of the master pump before the slave pump is changed over to individual
operation (jerk-free changeover).
Connection of unused, electrical All the analog inputs that are not used, e.g. actual pressure value input in the
signal inputs case of flow control, must be connected to 0 Volt.
In contrast to this, differential amplifier inputs that are not used may also be short-
circuited.
Product description
4.12.1 Activation sequence of electronics/hydraulics

General
Due to various monitoring routines integrated in the electronic assemblies, error
messages may be generated in the case of an unfavorable order of switching on.
These error messages cause uncertainties, although they have no real cause of
fault.
In principle, it is valid that all SY(H)DFEE control systems that are provided
exclusively with internal pilot oil supply automatically swivel to the operationally
safe zero stroke position in the event of a power failure. However, a precondition
for zero stroke is a minimum pressure between 8 and 12 bar, which the pump has
to build up as pilot pressure. This can always be ensured, when no oil can flow
away from the pump output (e.g. actuator line hydraulically blocked).
Please observe the special case of suspended loads!
Observe the following activation sequence:
Analog electronics ON: Voltage supply of the electronics

SYDFEE: Switch motor on and suppress error
message until star/delta changeover
takes place
Open check valve (if provided)
OFF: Command value provision:
SWAcomm = 5 % and p = 10 bar
Close check valve (if provided)
Suppress error message
Switch el. motor off
Switch voltage supply of electronics off
4.13 Identification of the product

The SY(H)DFEE control system can be identified with the help of the nameplate.
The figure below shows the example of a SY2HDFEE nameplate
Word mark
Material short text Material number
Date of production
Production job order no.
Rexroth MNR: R123456789 FD: 39022
SN: 0000001
SY2HDFEE-1X/125-045/R901038404+R90119184
Designation of origin 000120267633 Plant
7087
Made in Germany
Fabr. Nr 73939649 MINERALL

Dreh-
richtung
Fabrication number Direction of rotation
MADE . . . . . . . . . . . . . . . . . . .
Production location
Fig. 17: Nameplate
For queries with regard to the pump combination you must have the material
number and the fabriation number at hand.
5 Transport and storage
5.1 Transporting the SY(H)DFEE control system
DANGER! Risk of personal injury and damage to property!

When transported improperly, the SY(H)DFEE control system can fall down and
cause personal injury and/or damage to the control system, because parts may
have, for example, sharp edges, be heavy, oily, loose or bulky. Parts of the
SY(H)DFEE control system systems can be torn off or distorted.
f Ensure a stable position during transport to the place of installation.
f Wear personal protective equipment (such as gloves, safety shoes, protective
goggles, working clothes, etc.)
f Observe national laws and regulations regarding safety at work and health
protection and transport.
CAUTION! Risk of damage!

Hitting or impulsive forces on the drive shaft or the pilot valve can damage the
SY(H)DFEE control system.
f Do not hit the coupling or drive shaft of the axial piston unit.
f Do not set/place the axial piston unit on the drive shaft.
f Do not set/place the SY(H)DFEE control system on the pilot valve.
f Details on the permissible axial and radial forces on the shaft can be found in the
data sheet.
SY(H)DFEE control systems can be transported using a fork lift truck or lifting
gear.
f Make certain that the fork lift truck or lifting device has adequate lifting capacity.
Dimensions and weights Table 3: Dimensions and weights

SYDFEE 2X / size 18 28 45 71 100 140
Weight Pump without through- kg 14 17 23 35 47 62
In addition, pre-load valve kg 3,3 3,3 3,3 6,3 6,3 6,3
In addition, with external kg 2 2 2 2 2 2
actuating system supply
SYDFEE 3X / size 71 100 140

Weight Pump without through- kg 49 71 75
In addition, pre-load valve kg 6,3 6,3 6,3
In addition, with external kg 2 2 2
actuating system supply
SYHDFEE 1X / size 125 180 250 355

Weight Pump without through- kg 100 115 197 220
The dimensions vary depending on optional equipment. The values applicable to your
SY(H)DFEE control system can be found on the installation drawing or in the data sheet of
the relevant control system.
Carrying the SY(H)DFEE control SY(H)DFEE control systems of a low weight can be transported manually, if
system required (the weight for brief lifting should not exceed 15 kg for women and 25 for
men).
CAUTION! Risk of health damage!

Lifting heavy SY(H)DFEE control systems involves the risk of health damage.
f When transporting the SY(H)DFEE control system, apply suitable techniques
for lifting, lowering and relocating or use suitable lifting gear.
5.1.1 Transporting with lifting gear

Please observe the following points for transporting:
Properties of the load (e.g. weight, center of gravity, mounting and attachment
points).
Way of attaching or suspending the load
Make sure that the load carrying capacity of the lifting gear is sufficient for
transporting the SY(H)DFEE control system without any risks.
Use textile lifting slings in accordance with DIN EN 1492-2.
For further information on transportation, please contact Bosch Rexroth.
For transporting, the SY(H)DFEE control system can be connected to a lifting

device using a ring screw or a lifting strap.
Transport with ring screw The drive shaft can be used to transport the SY(H)DFEE control system as long
as only outward axial forces occur. Consequently, you can suspend the
SY(H)DFEE from the drive shaft.
f To do this, screw a ring screw completely into the female thread on the drive
shaft. The size of the thread is stated in the installation drawing.
f Make sure that each ring screw can bear the total weight of the SY(H)DFEE
control system plus approx. 20 %.
You can lift the SY(H)DFEE control system without any risk of damage as shown
in Fig. 18 using the ring screw screwed into the drive shaft.
Fig. 18: Fixing the ring screw
Transport with lifting strap f Place the lifting strap around the SY(H)DFEE control system in such a way
that it passes over neither the attachment parts (e.g. valves) nor such that the
SY(H)DFEE control system is hung from attachment parts (see Fig. 19).
WARNING! Risk of injury!

During transport with a lifting device, the control system can fall out of the lifting
strap and cause injuries.
f Hold the control system with your hands to prevent it from falling out of the
lifting strap.
f Use the widest possible lifting strap.
Fig. 19: Transport with lifting strap
Transport damage must be reported to your contact in the sales organization

within one week. You can find the addresses of our sales locations on the
Internet at:
http://www.boschrexroth.com/adressen
5.2 Storing the SY(H)DFEE control system

Some SY(H)DFEE control systems are shipped in an anti-corrosion foil (max.
storage time: 12 months). Without anti-corrosion foil, corrosion protection is
limited to transport (a few days). If these control systems are to be stored, then
you must provide preservation like for storage after disassembly (see below).
For storing SY(H)DFEE control systems in an anti-corrosion foil, the following
storage conditions apply:
Requirements The storage rooms must be free from corrosive materials and gases.
The storage rooms must be dry.
The ideal temperature for storage lies between +5 C and +20 C.
Avoid intense lights.
Do not stack SY(H)DFEE control systems and store them shock-proof and slip-
proof.
SY(H)DFEE control systems are very heay (see table 3 Dimensions and
weights on page 32). Also take account of the permissible useful loads of your
storage system.
f Check the SY(H)DFEE control system monthly for proper storage.
Procedure after expiration of the maximum storage time:

1. Check the entire SY(H)DFEE control system for damage and corrosion prior
to installation.
2. Check the SY(H)DFEE control system for proper function and leaks during a
test run.
3. Replace the shaft seal ring when the storage time of 24 months is exceeded.
After expiration of the maximum storage time, we recommend that you have
the SY(H)DFEE control system inspected by your responsible Rexroth Service
partner.
Should you have questions regarding spare parts, contact your responsible
Rexroth Service partner or the service department of the manufacturers plant for
the SY(H)DFEE control system, see Chapter 9.5 Spare parts on page 63 for
further information.
After disassembly If a dismounted SY(H)DFEE control system is to be stored, it must be preserved

against corrosion for the duration of storage.
The following instructions only refer to SY(H)DFEE control systems, which are
operated with a mineral-oil based hydraulic fluid. Other hydraulic fluids require
preservation methods that are specifically tailored to them. In such a case,
consult with the Rexroth Service (see Chapter 9.5 Spare parts on page 63
for address).
Rexroth recommends the following proceeding:

1. Clean the SY(H)DFEE control system, see also Chapter 9.1 Cleaning and
care, page 62.
2. Drain the SY(H)DFEE control system completely.
3. For storage times of more than 12 months: Wet the SY(H)DFEE control
system internally with mineral oil by filling in about 100 ml of mineral oil.
For storage time up to 24 months: Fill the SY(H)DFEE control system with
anti-corrosion agent VCI 329 (20 ml).
Filling via the case drain port.
4. Plug all ports air-tight.
5. Wet non-varnished external metal surfaces of the SY(H)DFEE control system
with mineral oil.
6. Pack the SY(H)DFEE control system air-tight together with a desiccant in an
anti-corrosion foil.
7. Protect the SY(H)DFE control system against impacts during storage. For
further conditions, see Requirements in this chapter.
Always observe the general laws and regulations when handling water-
endangering and harmful substances.
Installation
6 Installation
Before starting with the assembly and installation work, the following documents
must be available:
Hydraulic circuit diagram for the system (available from the system
manufacturer)
Data sheet of the SY(H)DFEE control system (contains the technical data)
Order confirmation (contains the preset data of the SY(H)DFEE control system)
6.1 Unpacking
CAUTION! Risk of parts falling out!

If the packaging is not opened correctly, parts may fall out and damage the parts
or even result in injury.
f Place the packaging on a flat and solid surface.
f Only open the packaging from the top.
Some SY(H)DFEE control systems are delivered in an anti-corrosion foil made of

polyethylene material.
f Dispose of the packaging according to the national regulations of your country.
6.2 Installation conditions

The installation orientation and position of the SY(H)DFEE control system
essentially determine the procedures during installation and commissioning
(such as when filling the SY(H)DFEE control system).
Note that you can expect certain installation positions to affect the control
behavior. Because of gravity, dead weight and case pressure, minor
characteristic curve offsets and actuating time changes may occur.
f Adhere to all limits specified in the data sheet regarding temperature,

viscosity, cleanliness of the hydraulic fluid.
f Make certain that the case of the SY(H)DFFEE control system is filled
with hydraulic fluid during commissioning and operation. This is also to be
observed following relatively long standstill periods as the SY(H)DFEE control
system may empty via the hydraulic lines.
f To achieve favorable noise values, decouple all connecting lines from all
components that can vibrate (e.g. tank) using elastic elements.
f Make certain that the suction line, case drain line, and return line flow into the
tank below the minimum fluid level in all operational states.
f Strictly observe extreme cleanliness. The SY(H)DFEE control system must be
installed without any contamination. Contamination of the hydraulic fluid can
significantly affect the service life of the SY(H)DFEE control system.
f Do not use any cotton waste or linty cloths for cleaning.
f Use suitable liquid detergents to remove lubricants and other difficult-to-
remove contamination. Detergents must not penetrate the hydraulic system.
Installation
CAUTION! Risk of damage by air inclusions!

An air pocket in the bearings will damage the SY(H)DFEE control system.
f Make certain that the pump case is completely filled with hydraulic fluid during
commissioning and during operation with the drive shaft upwards installation
position.
f During commissioning and during operation, the suction line must be filled
with hydraulic fluid.
CAUTION! Risk of damage due to hydraulic fluid loss!

With tank-top installation, the case interior may drain via the case drain line after
longer standstill periods (air enters via the shaft seal ring) or via the service line
(gap leakage). The bearings are thus insufficiently lubricated when the pump is
restarted.
f Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission.
6.3 Installation positions and piping of SY(H)DFEE

systems
6.3.1 General
The installation instructions are tailored to the use of the SY(H)DFEE control
system. Adhering to these instructions is a decisive factor for the service life of
the units.
The instructions refer to standard types and standard installation situations.
Particular installation situations require additional measures to be taken on the
unit, which are documented separately.
Generally, care must be taken that during commissioning and re-commissioning
of a system or equipment, the entire case of the axial piston unit is filled with
hydraulic fluid and remains filled during operation.
CAUTION! Risk of damage due to lack of hydraulic fluid!

Commissioning or re-commissioning of the unit without or with insufficient
hydraulic fluid in the case interior results in damage to or destruction of the rotary
group.
f Make certain that the pump case is filled with hydraulic fluid. An optimum filling
orientation is assigned to each type. Only this orientation allows complete
filling of the case, which is the reason why this orientation must be adhered
to during commissioning. For re-commissioning, this orientation should be
complied with as far as possible.
In the following, we distinguish between the installation position (pump/motor in

relation to tank) and the installation orientation (position of the pump/motor shaft
end vertical, horizontal, etc.).
The following installation positions are permitted. The pipe routing shown
represents the general routing.
Installation position The following installation positions are possible (see Fig. 20):
Pos. a): Pump/motor above the tank (above minimum oil level)
Pos. b): Pump/motor next to or below the tank (below minimum oil level), with
the upper edge of the case corresponsing to the minimum oil level
Installation
Pos. c): Pump/motor in the tank (below minimum oil level). SY(H)DFEE control
systems cannot be installed in the tank. Use control system (SY(H)DFE1 for
oil-immersed applications.
a
+
=
- b
SYD 015
Fig. 20: Installation position
Installation orientation The following installation orientations are possible (see Fig. 21):
Pos.1 horizontal: Shaft end horizontal
Pos.2 vertical: Shaft end upwards
Pos.3 vertical: Shaft end downwards
1 2 3
SYD_016
Fig. 21: Installation orientations
6.3.2 Piping
The installation positions and installation orientations shown in Figs. 20 and 21
determine the installation of
suction lines
case drain lines
bleed lines.
Make sure for all installation positions that always the higher of drain ports L
or L1 is piped. Moreover, the distance between the end of installed pipes and
the minimum oil level must not be shorter than the specified minimum distance
(immersion depth E).
Special points When installing suction and drain lines, take care that the routing is straight, short
and has as few bends as possible.
When the system is at rest, the lines drain automatically in the course of time due
to the own weight of the hydraulic fluid.
Installation
Moreover, the different specific densities of hydraulic fluids must be taken into
account, since fluids with a higher density are more difficult to aspire and also
flow down more quickly. The limit speeds for hydraulic fluids with high density (
mineral oil 0.87 g/ml) are specified in data sheet RE 90223.
For pumps, a minimum suction pressure is prescribed for port S irrespective of
installation positions and installation orientations:
minimum suction pressure 0.8 bar abs.
To establish the suction pressure (inlet pressure) pabs in dependence on the
displacement or speed, please observe the technical data given in data sheets
RE 30030, 30630 and 30035.
CAUTION! Damage to the SY(H)DFEE control systems!

Pressure values below the specified value can result in damage or destruction of
the unit.
f For this reason, make sure that the pressure does not fall below the
prescribed minimum value.
0,8 abs. -0,2
Absolute 1 0 Standard
0 2 -1 1
pressure pressure
3 2
gauge gauge
SYD 017
Fig. 22: Minimum suction pressure
Case drain piping Dynamic swiveling processes result in increased case pressures that are caused
by the acceleration phase of the drain oil column. They occur within milliseconds
and must not exceed 6 barabs.. They are influenced by the inductive resistance of
the case drain line (pi = f (diameter, length)). Here, the flow resistance at the
case drain fitting on the pump case plays a subordinate role.
The pi value can only be improved by a larger nominal width of the case
drain line.
General notes Generally, the following must be observed:

f Each pump should preferably be piped with a separate case drain line.
Installation
f Direct the case drain fluid in the case chamber via the highest case drain
port as short as possible (ca. 1 m) directly to the tank. Use a pipe size, which
corresponds to the port.
f When the specified line lengths are exceeded we recommend that the nominal
width be increased by one size per additional meter.
f The nominal width of the case drain line determined by the threaded
connection on the pump case must not be reduced. Use light series pipes
only.
f Do not use check valves in case drain lines.
f The case drain line should always enter the tank in the return flow chamber
below the oil level. For tank designs without direct separation of the suction
chamber, the drain line should be returned to the tank as far away as possible
from the suction port.
f External influences of pressure, e.g. from manifold tank lines, on the pump
drain port or the pump case are not permitted.
6.4 Installing the SY(H)DFEE control system
DANGER! Risk of injury through systems which were not shut down!
Working on running systems poses a danger to life and limb. The work steps
described in this chapter must only be performed on systems which are at a
standstill. Before beginning work:
f Make sure that the drive motor cannot be switched on.
f Make sure that all power-transmitting components and connections (electric,
pneumatic, hydraulic) are switched off according to the manufacturers
instructions and are secured against being switched on again. If possible,
remove the main fuse of the system.
f Ensure that the system is completely hydraulically relieved and depressurized.
Please follow the system manufacturers instructions.
f Only qualified personnel (see Chapter 2.3 Personnel qualifications on page
8) are authorized to install the SY(H)DFEE control system.
6.4.1 Preparation
1. Check the delivery contents for completeness and transport damage.
2. Compare the material number and designation (ordering code) with the details
on the order confirmation.
If the material number for the SY(H)DFEE control system does not correspond
to the one on the order confirmation, contact Rexroth Service for clarification,
see Chapter 9.5 Spare parts on page 63 for address.
3. Before installing the SY(H)DFEE control system, completely empty it to

prevent mixing with the hydraulic fluid used in the system.
4. Check the direction of rotation of the SY(H)DFEE control system (on the
nameplate) and make sure that this corresponds to the direction of rotation of
the motor.
Installation
The direction of rotation as specified on the nameplate determines the

direction of rotation of the SY(H)DFEE control system as viewed on the drive
shaft. For information on the direction of rotation of the motor, please refer to
the motor manufacturers operating instructions.
CAUTION! Damage caused by missing seals and plugs!

Fluids and foreign particles can get into the product and destroy it.
f Before starting the installation make sure that all seals and plugs of the
connections are tight.
CAUTION! Risk caused by incorrect mounting of the SY(H)DFEE control system!

An improperly mounted SY(H)DFEE control system can move in an uncontrolled
manner and damage other system parts.
f Make sure that the SY(H)DFEE control system is properly mounted.
6.4.2 Dimensions
The data sheet contains the dimensions for all connections to the SY(H)DFEE
control system. Also observe the instructions provided by the manufacturers of
the other components when selecting the required tools.
6.4.3 General notes

When installing and uninstalling the SY(H)DFEE control system, observe the
following general notes and instructions for action:
f Mount the SY(H)DFEE control system so that the expected forces and torques
can be transmitted without any risks.
f The permissible axial and radial loading of the drive shaft, the permissible
torsional vibration, the optimum direction of load force, as well as the limit
speeds can be found in the data sheet.

Hitting or impulsive forces on the drive shaft can damage the SY(H)DFEE control
system.
f Do not hit the coupling or drive shaft of the SY(H)DFEE control system.
f Do not set/place the SY(H)DFEE control system on the drive shaft.
f Details on the permissible axial and radial forces can be found in the data
sheet.
6.4.4 Installation with coupling

The SY(H)DFEE control system is usually flange-mounted to a motor with a
coupling. If you plan to install the unit otherwise, please consult us.
How to install the axial piston unit with a coupling is described in detail in the
following:
1. Mount the relevant coupling half onto the drive shaft of the SY(H)DFEE control
system according to the instructions of the coupling manufacturer.
Installation
The drive shaft end of the SY(H)DFEE control system is provided with a
threaded bore. Use this threaded bore to pull the coupling element onto the
drive shaft. Refer to the installation drawing for the dimensions of the threaded
bore.
2. Make sure that the installation location is clean and free from dirt and foreign
particles.
3. Fix the coupling hub on the drive shaft or ensure permanent lubrication of the
drive shaft. This prevents the formation of frictional corrosion and associated
wear.
4. Transport the SY(H)DFEE control system to the installation location.
5. Mount the coupling to the drive in accordance with the instructions of the
coupling manufacturer.
The SY(H)DFEE control system must not be tightened down until the coupling
has been correctly assembled.
6. Mount the SY(H)DFEE control system at the installation location.

7. If necessary, details on the required tools and tightening torques for the
mounting screws are available from the machine or system manufacturer.
For bell housing installation, check the coupling axial play through the
bell window according to the instructions of the machine or system
manufacturer.
For flange installation, align the support of the SY(H)DFEE control system
with the drive.
8. When using flexible couplings, check that the drive is free of resonance after
having completed the installation.
6.4.5 Completing the installation

1. Remove transport screws, if fitted.
2. Remove the transport protection.
The axial piston unit of the SY(H)DFEE control system was delivered with
protective covers and plastic plugs or plug screws. These must be removed
before connecting the system. Use appropriate tools.
3. Make certain that the sealing and functional surfaces are not damaged.
CAUTION! Risk of personal injury and damage to equipment!

Operating the SY(H)DFEE control system with plastic plugs can cause injuries or
damage to the SY(H)DFEE control system.
f Before commissioning, remove all plastic plugs and replace them with
suitable, pressure-proof metal plug screws, because plastic plugs are not
pressure-proof.
Setscrews, if provided, are protected against unauthorized resetting by means

of protective caps. Removing protective caps will void the warranty. If you
need to modify the setting, please contact the responsible Rexroth Service (for
address, see Chapter 9.5 Spare parts on page 63).
For the variant with through-drive, mount the auxiliary pump in accordance
with the instructions of the pump manufacturer.
Installation
6.5 Connecting the SY(H)DFEE control system

hydraulically
The machine or system manufacturer is responsible for dimensioning the lines.
The SY(H)DFEE control system must be connected to the rest of the hydraulic
system in accordance with the hydraulic circuit diagram of the machine or system
manufacturer.
CAUTION! Damage to the SY(H)DFEE control system!

Hydraulic pipes and hoses, which are installed under mechanical stress, generate
additional forces during operation, which reduces the service life of the
SY(H)DFEE control system and the machine or system as a whole.
f Install pipes and hoses stess-free.

Generally, a minimum permissible suction pressure at port S is specified for
SY(H)DFEE control systems in all installation positions. If the pressure at port
S drops below the specified values, damage may occur which may lead to the
destruction of the SY(H)DFEE control system.
f Make certain that the necessary suction pressure is achieved.
This is influenced by:
appropriate piping of the suction cross-sections
appropriate pipe diameters
appropriate position of the tank
appropriate viscosity of the hydraulic fluid
Connect only hydraulic lines to the service and function ports.
CAUTION! Wear and malfunction!

The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and service life of the hydraulic system. Any contamination of the hydraulic fluid
leads to wear and malfunctions. In particular, contaminants like e.g. welding
beads or metal cuttings in the hydraulic lines may damage the SY(H)DFEE
control system.
f Ensure utmost cleanliness.
f The SY(H)DFEE control system must be installed in a clean condition.
f Make sure that all ports, hydraulic lines and add-on units (e.g. measuring
devices) are clean.
f Make sure that no contaminants can enter the system when you close the
ports.
f Make sure that no detergents enter the hydraulic system.
f Do not use any cotton waste or linty cloths for cleaning.
f Never use hemp as sealant.
Notes on routing of lines Observe the following notes when routing the suction, pressure and case drain
lines.
f See to it that the suction line (pipe or hose) is as short and straight as
possible.
f The line cross-section of the suction line is to be dimensioned so that the
pressure in the suction port does not fall below the minimum permissible value
and the maximum permissible pressure is not exceeded.
f Observe air tightness of the junctions and pressure resistance of the hose,
also with respect to the external air pressure.
Installation
f In conjunction with the pressure lines, make certain that the pipes, hoses and
connecting elements are approved for the operating pressure range.
f Always route the case drain lines so that the housing is constantly filled with
hydraulic fluid and ensure that no air gets through the shaft seal ring even
during extended standstill periods. The pressure inside the case must not
exceed the limit values specified for the SY(H)DFEE control system in the
data sheet under any operating conditions. The case drain line in the tank
must in any case end up below the minimum fluid level (see Chapter 6.3
Installation positions on page 37).
The ports and mounting threads are designed for the operating pressures
specified in the data sheet. The machine or system manufacturer must ensure
that the connecting elements and lines comply with the specified operating
conditions (pressure, flow, hydraulic fluid, temperature) with the necessary
safety factors.
The pressure port of the SYDFEE control system of size 71 is provided with
threads for two standard flange patterns:
SAE 1 (dot-and-dashed line) for pressures above 250 bar and
SAE 1 (dotted line) for pressures up to 250 bar.
Because standard flanges according to SAE 1 are permitted up to 250 bar
only, the porting pattern to SAE 1 must be used in the case of operating
pressures higher than 250 bar.
Fig. 23: Flange pattern
Procedure To connect the SY(H)DFEE control system to the hydraulic system:

1. Remove the plug screws from the ports that are to be connected according to
the hydraulic circuit diagram.
2. Use only clean hydraulic lines.
3. Connect the lines according to the hydraulic circuit diagram.
Either pipes or hoses must be connected to all ports according to the
installation drawing and machine or system circuit diagram or the ports
plugged using suitable plug screws.
The installation drawing contains the dimensions of all connections and ports
on the SY(H)DFEE control system. Also observe the instructions provided by
the manufacturers of the other hydraulic components when selecting the
required tools.
Installation
4. Make sure
that the cap nuts are correctly tightened on the fittings and flanges (observe
tightening torques!). Mark all checked fittings using e.g. a permanent
marker,
that the pipes and hose lines and every combination of connecting pieces,
couplings or connecting points with hoses or pipes have been inspected by
a technically qualified person for their safe working condition.
Tightening torques The tightening torques for the SY(H)DFEE control system are listed in the
following table:
Threaded hole in the axial piston unit:
The maximum permissible tightening torques MGmax are the maximum
values of the threaded holes and must not be exceeded.
Fittings:
Observe the manufacturers instructions regarding tightening torques for the
fittings used.
Mounting screws:
For mounting screws according to DIN 13/ISO 68, we recommend checking
the tightening torque in each individual case as per VDI 2230.
Plug screws:
For the metal plug screws that come with the SY(H)DFEE control system,
the required tightening torques of plug screws MV apply.
Risk of mix-ups with threaded SY(H)DFEE control systems are used in applications with metric as well as with
connections imperial systems of units.
Both, the system of units as well as the size of threaded hole and threaded plug
(e.g. plug screw) must match.
Since the systems cannot be distinguished visually, there is a risk of mixing up.
WARNING! Risk of personal injury and damage to property!

If a threaded plug is used that differs from the threaded hole in terms of unit
system and size and is pressurized, the threaded plug may loosen itself or even
be ejected from the hole in a projectile-like manner.
This can result in serious injury and damage to equipment. Hydraulic fluid can be
discharged from this leakage point.
f Use the drawings (installation drawing/data sheet) to determine the required
threaded plug for each fitting.
f Make certain that there are no mix-ups when assembling valves, mounting
screws and plug screws.
f For all threaded holes, use a threaded plug from the same system of units and
of the correct size.
Installation
Table 4: Tightening torques of threaded holes and plug screws
Max. permissible tightening Required tightening torques for

Thread size of ports A/F hexagon socket
torque of threaded holes MGmax plug screws MV
M10x1 DIN 3852 30 Nm 12 Nm 5 mm

M12x1,5 DIN 3852 50 Nm 25 Nm 6 mm
M14x1,5 DIN 3852 80 Nm 35 Nm 6 mm
M16x1,5 DIN 3852 100 Nm 50 Nm 8 mm
M18x1,5 DIN 3852 140 Nm 60 Nm 8 mm
M22x1,5 DIN 3852 210 Nm 80 Nm 10 mm
M26x1,5 DIN 3852 230 Nm 120 Nm 12 mm
M27x2 DIN 3852 330 Nm 135 Nm 12 mm
M33x2 DIN 3852 540 Nm 225 Nm 17 mm
M42x2 DIN 3852 720 Nm 360 Nm 22 mm
5/16-24 UNF-2B ISO 11926 10 Nm 7 Nm 1/8 in
3/8-24 UNF-2B ISO 11926 20 Nm 7 Nm 5/32 in
7/16-20 UNF-2B ISO 11926 40 Nm 15 Nm 3/16 in
9/16-18 UNF-2B ISO 11926 80 Nm 25 Nm 1/4 in
3/4-16 UNF-2B ISO 11926 160 Nm 62 Nm 5/16 in
7/8-14 UNF-2B ISO 11926 240 Nm 127 Nm 3/8 in
1 1/16-12 UN-2B ISO 11926 360 Nm 147 Nm 9/16 in
1 5/16-12 UN-2B ISO 11926 540 Nm 198 Nm 5/8 in
1 5/8-12 UN-2B ISO 11926 960 Nm 320 Nm 3/4 in
1 7/8-12 UN-2B ISO 11926 1200 Nm 390 Nm 3/4 in
For the tightening torques for spare parts, please refer to the data sheet.
6.6 Connecting the SY(H)DFEE control system

electrically
The machine or system manufacturer is responsible for the layout of the electrical
control.
For electrically controlled SY(H)DFEE control systems, the electrical control must be
connected according to the circuit diagram of the machine or system manufacturer.
CAUTION! Risk of injury due to live installation!

Plugging and unplugging plug-in connectors under voltage destroys the
SY(H)DFEE control system!
If you do not switch off the power supply before you start the installation, you may
injure yourself, destroy the product or damage system components.
f Always de-energize the relevant system part before you install the product or
plug or unplug plug-in connectors.
1. Disconnect the relevant system part from the power supply.

2. Connect the SY(H)DFEE control system electrically (24 V).
CAUTION! Risk of short-circuit!

Fluid can enter the product and cause a short-circuit.
f Do not install the SY(H)DFEE control system below the fluid level in a tank
(in-tank installation).
Installation
6.6.1 Cabling of electronic components

Generally, the following is valid:
Keep the number of intermediate terminals to a minimum.
The arrangement of electromagnetic sources of interference in the direct
vicinity of the pilot valve is not permitted.
Installing power cables in the vincinity of the pilot valve is not permitted.
Due to the use in a hydraulic environment, use only cable material that is
specified as oil-proof. Otherwise, possible hardening of the cable jacket
could lead to embrittlement and thus to breaking of individual wires.
Select only cables that have the actually required number of wires (avoid
superfluous wires).
Cables for command values and actual values should be as short as
possible.
The signal cable to the pilot valve must in any case be shielded. The cable
shield must be connected to ground on one end in the control cabinet.
Strip the shield as short as possible and connect it in accordance with the
data given in the RE data sheets.
The contacts on the mating connector must not be exposed to mechanical
stress. This can lead to a defective connection between the mating
connector and the plug-in connector.
Fig. 24: Protection of contacts
Due to the fact that the control electronics is integrated in the valve housing in the
factory, no additional cabling is required for the position transducer systems of the
pump and the valve.
Cabling of the control system is therefore restricted to the connection of the 12-pin
central connector of the integrated electronics to the customers control and the
pressure sensor, if provided.
For this connection, ready-to-connect and standardized cable kits are available
in different lengths. On request, the 12-pin mating connector can be supplied
separately for individual designs.
The HM16-1X/C13 pressure transducer is fitted with a ready-to-connect,
standardized connection cable for direct connection to the VT-DFPE-x-2X/...F...
electronics.
6.6.2 Power supply of the VT-DFPE pilot valve

The pilot valve VT-DFP is supplied with 24 V DC voltage. If this voltage supply
is not provided on the part of the system, power supply unit VT 19 085 (NE32)
according to RE 29929 can be used. The 24 V supply of the power supply unit is
to be connected to connections 1 (+24 V) and 2 (L0) of the mating connector.
Installation
In the case of the connection cable optionally available, this refers to the 2 black
wires of the 3-pin cables with a cross-section of 1 mm. Connect the wire marked
with 1 to +24 V and the wire marked with 2 to L0 (ground). Connect the yellow/
green wire to ground.
Connection cable for signals
Green/yellow =
Black (1) = Black (2) =

pin 2 pin 2
Connection cable for +24 V 0 V Ground
voltage supply connection
Socket on VT-DFP
Fig. 25: Connection of power supply
Recommendation:
The voltage supply for the VT-DFP.. pilot valve should be proteced with a 1.6 A/
slow-blowing fuse on the system side.
The pilot valve is not provided with an enable input to block the function of the
valve.
In the case of a fault, the pilot valve should be de-energized. Any further
safety-relevant interventions must be made by the higher-level control (e.g.
drive motor OFF, check valves closed, ...).
6.6.3 Selection, place of installation and mounting orientation of

the pressure transducer
Selection of the pressure To reduce the number of variants, only pressure rating 315 bar is given in the
transducers ordering code of the SY(H)DFEE control systems. If required, other pressure
ratings can be combined (with the correct selection of the relevant electrical
interface!). Such pressure transducers must, however, be ordered separately for
the SY(H)DFEE control system.
In terms of signals, the sensors have to be distinguished as follows
Sensors with current interface
Sensors with voltage interface.
Here, the usual signal limits are between 0...20 mA or 0...10 V, respectively.
Within these limits, there are further modifications that depend on further options,
such as monitoring for cable break.
From a technical point of view, the efficiency of the pressure transducer must be
adapted to the SY(H)DFEE system in order that the best possible results can be
obtained with regard to accuracy, dynamics and repeatability.
The pressure transducers recommended by us are listed in the RE data sheets of
the relevant SY(H)DFEE system.
Our pressure transducer model HM12 with current interface (4 20 mA) is
provided with a 2-conductor connection and allows the fail-safe transmission of
signals even over greater distances.
Further pick-offs can be looped in taking into account the relevant input
resistances.
Installation
Our pressure transducer model HM13 with voltage interface (0...10 V) has a
3-conductor connection and an integrated DC/DC converter, which effectively
rules out disturbances on the analog signal caused by the voltage supply.
The HM16-1X/C13 pressure transducer has a voltage interface (0.5...5 V) with
a ready-to-connect, standardized connection cable for direct connection to the
VT-DFPE-x-2X/...F... electronics.
CAUTION! Uncontrolled increase in pressure!

If no pressure signal is available, the control electronics can no longer recognize
the pressure. This can result in an uncontrolled increase in pressure.
f The pressure transducer must be wired so that it cannot be short-circuited.
Place of installation of the pressure Favorable places of installation of pressure transducers turned out to be not in the
transducer direct vicinity of the pump, but, for example, downstream of the (flexible) pressure
hose:
Always between pump and check valve (if fitted)
Do not use minimess lines
The installation in the pump case or in port MP1 of the SYDZ pre-load valve
is, due to more stringent demands made on signal processing (pressure
pulsation), approved only for the combination of SYDFEE-2X and
HM16-1X/C13, since these control electronics allow a corresponding
adjustment for this or are modified accordingly.
Mounting orientation of the We recommend suspended mounting of the pressure transducer so that bleeding
pressure transducer problems (and hence control oscillations) can be ruled out right from the start.
If, due to the installation orientation of the pump, a pressure transducer must
be installed vertically directly in the pump or in the pre-load valve, we
recommend another place of installation for the pressure transducer.
Voltage supply and connection of Pressure transducers for direct connection to valves with integrated electronics.
the pressure transducer it is optionally possible to connect pressure transducers of type HM16-1X/C13
directly to the electronics integrated in the valve using an M12 plug-in connector.
For this variant, feature 14 in the type code is F. Example:
SYDFE-2X/018R-PPA12N00-0000-A0AOFL1. Since both, cabling and voltage
supply, are fixed in this case, these points do not require particular attention.
An additional connection of the actual pressure value input via the 12-pin central
connection is not permitted!
A precondition for the direct electrical connection of this special pressure transducer
model is, however, the selection of valve variant VT-DFPE-x-2X provided for this
purpose that must be selected with order option F in the type code.
The operation of the SYDFEE-2X control system with the HM16-1X/C13
pressure transducer mounted directly on the pump is only permitted in
conjunction with the use of special electronics with reduced P-gain.
Installation
HM12 Pressure transducers of type HM12-1X are provided with a 2-wire current
interface and can be connected to the pilot valve using the central plug-in
connection as shown on the figure below.
with the specification.
For more details about the pressure transducers HM12 and HM13, see RE 29933.
+24 V
+24 V
to pact High = 4-20 mA

pin 10
to pact Low =
pin 11
L0
Fig. 26: Connections of HM12
HM13 Pressure transducers of type HM13 are provided with a voltage output of 0...
+10 V as actual pressure value signal and can be connected to the pilot valve
using the central plug as shown on the figure below.
with the specification.
For more details about the pressure transducers HM12 and HM13, see RE 29933.
+24 V
to pact HIGH =
pin 10 0V
to pact LOW =
pin 11
L0
Fig. 27: Connections of HM13

Commissioning
7 Commissioning
WARNING! Danger while working in the danger zone of a machine or system!
It is not permissible to work in the danger zone of a machine or system.
f The machine or system may only be operated if safe working is ensured.
f Pay attention to and eliminate potential danger sources before commissioning
f Nobody may stand in the danger zone of the machine or system.
f The emergency stop button for the machine or system must be within the
operators reach.
f Always strictly observe the instructions of the machine or system manufacturer
during commissioning.
CAUTION! Risk of personal injury and damage to property!

Commissioning of the SY(H)DFEE control system requires basic mechanical,
hydraulic and electrical knowledge.
f Only qualified personnel (see Chapter 2.3 Personnel qualifications on page
8) are authorized to commission the SY(H)DFEE control system.
WARNING! Risk of toxication and injury!

Contact with hydraulic fluids may damage your health (e.g. eye injuries, skin
damage, toxication upon inhalation).
f Always check the lines for wear and damage before each commissioning.
f While performing these checks, wear safety gloves, safety glasses and
suitable working clothes.
f If hydraulic fluid should, nevertheless, come into contact with your eyes or
penetrate your skin, consult a doctor immediately.
f When working with hydraulic fluids, strictly observe the safety instructions
provided by the hydraulic fluid manufacturer.
WARNING! Fire hazard!

Hydraulic fluid is easily flammable.
f Keep open flames and ignition sources from the SY(H)DFEE control system.
CAUTION! Missing seals and connections lead to non-compliance with the protection
class!
Fluids and contaminants may penetrate and damage the product.
f Prior to assembly, make sure that all seals and plug-in connections are tight.
Commissioning
7.1 First commissioning
CAUTION! Risk of damage to the product!

Any contamination of the hydraulic fluid leads to wear and malfunction. In
particular, contaminants like e.g. welding beads or metal cuttings in the hydraulic
lines may damage the SY(H)DFEE control system.
f Ensure utmost cleanliness during commissioning.
f Make sure that no contaminants penetrate when closing the measuring ports.

If you commission the SY(H)DFEE control system without or with insufficient
hydraulic fluid, the control system is damaged immediately or even destroyed.
f When commissioning or recommissioning a machine or system, make sure
that the case interior and the suction and service lines of the SY(H)DFEE
control system are filled with hydraulic fluid and remain filled during operation.
When commissioning the SY(H)DFEE control system, observe the basic

safety instructions and intended use provided in Chapter 2 General safety
instructions on page 7.
7.1.1 Filling the SY(H)DFEE control system

You will require an approved hydraulic fluid:
The machine or system manufacturer can provide you with precise data of the
hydraulic fluid. Details on minimum requirements for mineral-oil based hydraulic
fluids or HFC hydraulic fluids (only for SYHDFEE with option F) are available in
the Rexroth publications RE 92053 and RE 90223, respectively.
To ensure the functional reliability of the SY(H)DFEE control system, the hydraulic
fluid must comply at least with cleanliness class 18/16/13 according to ISO 4406
for the hydraulic fluid for particle sizes 4/6/14 m. For permissible temperatures,
see Chapter 4.7 Notes on the selection of hydraulic fluids on page 23.

An air pocket in the bearings will damage the SY(H)DFEE control system.
f In the case of installation position drive shaft upwards, make certain that the
pump case is completely filled with hydraulic fluid during commissioning and
during operation.
f Check the hydraulic fluid level in the case interior regularly; if necessary,
recommission. With tank-top installation, the case interior may drain via the
case drain line after longer standstill periods (air enters via the shaft seal
ring) or via the service line (gap leakage). The bearings are thus insufficiently
lubricated when the pump is restarted.
f Make certain that the suction line is always filled with hydraulic fluid during
commissioning and operation.
The SY(H)DFEE control system should be filled using a filling and filtration
unit (10 m filtration rating). The control system must not be powered when
being filled.
Commissioning
CAUTION! Danger of environmental pollution!

The discharge or spillage of hydraulic fluid while filling the SY(H)DFEE control
system can lead to environmental pollution and contamination of the groundwater.
f When filling and changing the hydraulic fluid, always place a catch pan under
f Observe the information in the safety data sheet for the hydraulic fluid and the
specifications provided by the system manufacturer.
1. Fill and air bleed the SY(H)DFEE control system via the appropriate ports,
see Chapter 6.3 Installation position on page 37. The hydraulic lines of the
system must also be filled.
2. Test the direction of rotation of the motor. To do this, rotate the motor briefly at
the lowest rotational speed (inching). Make sure that the direction of rotation
of the axial piston unit corresponds to the indication on the nameplate, see
also Chapter 4.12 Product identification, Fig. 17: Nameplate on page 31.
3. Operate the SY(H)DFEE control system at low speed (inching) until the
pump system is completely filled and bled. For checking purposes, drain the
hydraulic fluid at the case drain port and wait until it drains without bubbles.
4. Make certain that all ports are either connected to pipes or plugged according
to the general circuit diagram.
7.1.2 Performing a flushing cycle

To remove foreign particles from the system, perform a flushing run for the entire
system.
Flushing is to be carried out with an additional flushing power unit. Observe
the instructions of the flushing unit manufacturer for the detailed procedure for
carrying out the flushing cycle.
7.1.3 Switching on the supply voltage for the electronics

The activation sequence for electronics/hydraulics is described in section 4.12.1
Activation sequence of electronics/hydraulics on page 30.
At this point, the pump drive motor should be switched off. When switching on the
power supply for the first time the command values for the electronics should be
provided as follows.
Pressure command value (pcomm) = 0.1 V
Flow command value (comm) = 10 V
After having switched on the power supply (motor is still switched off!), you should
check the following points:
1. The fault signal output ERROR (pin 3) is in state HIGH (=24 V / reference
L0).
2. The swivel angle SWAact (pin 6) of the pump is within the range of
+10 V 0.3 V (positive stop / reference M0 = pin 4).
If this state is not reached, a fault must have occurred.
The following faults are conceivable:
Power supply not available
Check power supply at the central plug-in connector of the electronics.
Fault in the pressure measuring branch
Measure the actual pressure value pact (pin 8) (must be 0 V). In the case
of a negative voltage of about -0.5 V or less, a cable break message is
Commissioning
generated. The output signal of the pressure transducer must be compatible

with the type of the control electronics (current, voltage, zero point).
Fault in the swivel angle measuring branch
Measure the actual swivel angle value SWAact (pin 6). In the case of
deviations from value +10 V 250 mV, inspect the cable connection.
Further explanations on the analysis of faults can be found in Chapter 14.

Troubleshooting on page 70.
7.1.4 Switching on the drive motor of the pump

1. Close all directional valves.
2. Before cutting in the motor, apply the following command values to the pilot
valve:
Pressure command value (pcomm) = 1.0 V 31.5 bar
Flow command value (SWAcomm) = 2.0 V 20 %
These values are valid when you use our standard pressure transducer with a
measuring range of 0...315 bar.
In this state the VT-DFP pilot valve signals a fault (excessive control error).
When the control system works correctly, this fault signal disappears after the
motor has been switched on (control deviation now equal to zero).
The hydraulic fluid should have reached operating temperature before you
continue with further commissioning.
For initial commissioning, limit the pressure to max. 50 bar.
7.1.5 Bleeding the pre-load valve

When a pump unit is operated with a pre-load valve, this valve must be air-bled
for the initial start-up, if the pump does not deliver and aspire oil. Bleeding is
not required, when the pump displaces oil. Bleed the pump while the system
is running at low operating pressure. To this end, loosen the screw (see figure
below) by a maximum of 2 turns and wait until bubble-free oil flows out. Then,
re-tighten the screw.
Bleed screw
Fig. 28: Bleeding of the pre-load valve

Commissioning
CAUTION! Risk of injury!

The case interior is pressurized to high pressure! Turning the bleed screw out too
far can cause parts and hydraulic fluid to be ejected under pressure!
f Do not turn the bleed screw out too far (max. 2 turns)!
7.1.6 Testing the hydraulic fluid supply

The SY(H)DFEE control system must always be supplied with sufficient hydraulic
fluid. For this reason, the supply of hydraulic fluid must be ensured at the start of
the commissioning process.
When you test the hydraulic fluid supply, constantly monitor the noise
development and check the hydraulic fluid level in the tank. If the SY(H)DFEE
control system becomes louder (cavitation) or the case drain fluid flows out with
bubbles, this is an indication that the SY(H)DFEE control system is not being
sufficiently supplied with hydraulic fluid.
Notes on troubleshooting can be found in Chapter 14 Troubleshooting on page
70.
To test the hydraulic fluid supply:
1. Allow the motor to run at slowest speed. The SY(H)DFEE control system must
be operated under no-load conditions. Pay attention to leakage and noise.
2. Check the SY(H)DFEE control systems case drain line during the test. The
case drain fluid should not contain any bubbles.
3. Check the suction pressure at port S of the SY(H)DFEE control system
pump. For the permissible value, please refer to data sheet RE 30030,
RE 30630 and RE 30035.
4 Check the case drain pressure at connected port K1 or K2. Refer to data
sheets RE 30030, RE 30630 and RE 30035 for permissible values.
7.1.7 Possible adjustment work on the SYDFEE system

The operating pressure is the pressure level, which the pump system is to
generate as maximum value in the system.
The signal level of the pressure transducer, which is connected to the pump
system, is converted into the normalized level of 0...10 V in the pilot valve and
passed on as actual pressure value to the pressure controller.
The normalized actual pressure value can be measured at central plug-in
connector pin 6 (reference M0 = pin 4).
Depending on the variant of the pilot valve, the corresponding pressure
transducer signal is converted into the signal level of 0...10 V (factory default
setting of the system).
Some examples:
4...20 mA is converted into 0...10 V (variant C in the type code)
1...10 V is converted into 0...10 V (variant E in the type code)
The pressure controller of the SY(H)DFEE.. system compares the level at

the command value input (0...10 V) with the converted actual pressure value
(0...10 V).
If the measuring range of the pressure transducer does not correspond to the
operating pressure, controlling will not be based on the value of the operating
pressure when the maximum pressure value is applied (+10 V), but on the final
value of the pressure transducer measuring range.
Commissioning
2 adjustment options are provided:

Actual pressure value adjustment
Pressure command value For pressure command value adjustment, the pressure command value is
adjustment normalized to the measuring range of the pressure transducer and fed forward
accordingly.
With this procedure, no adjustment work is necessary on the pilot valve. This
is especially advantageous in the case of pump systems, which are difficult to
access.
Example:
Measuring range of the
standard pressure transducer: 0... 315 bar
Selected operating pressure: 250 bar
The following is valid for the pressure value provision:
10 V / 315 bar = 31.7 mV/bar (= factor)
250 bar x 31.7 mV/bar = 7.94 V
This means that the pressure command value is normalized to the factor of
31.7 mV/bar.
In order to be able to feed the operating pressure value forward as pressure
command value, a pressure command value of 7.94 V must be generated.
General formula:
Factor: 10 V / measuring range of the pressure transducer
Pressure command
value [bar]: Pressure x factor = pressure command value [V]
Actual pressure value In the case of actual pressure value adjustment, the actual pressure value is
adjustment normalized to the operating pressure.
With the factory setting, pilot valve VT-DFPE-2X.. converts the signal of the
pressure transducer internally into the range of 0... +10 V.
The signal range (= gain) of the actual pressure value can be changed with the
help of potentiometer R2, which is located behind a screw on the pilot valve.
Proceeding while the system is running:
1. Close all directional valves. No fluid is allowed to flow.
2. Apply a swivel angle command value of > 5 V.
3. Use potentiometer R2 behind the screw on the housing cover (see figure
below) to adjust the operating pressure.
R2: Adjustment of operating pressure
Connection cable to swivel angle transducer

Fig. 29: Actual pressure value adjustment
4. Set the pressure command value to 5.00 V (= half operating pressure). After
this, adjust the potentiometer until exactly half the operating pressure is
Commissioning
reached. For checking purposes, the max. operating pressure (pmax / 3 bar)
must be obtained at a command value of +10.0 V.
When you turn the potentiometer clockwise, the gain is reduced, that is, the
pressure level is increased.
7.1.8 Optimizing the pressure controller

A decisive influence on the control dynamics of the pressure control loop has the
oil volume between the actuator and the pump. Rotary switch S1 is used to match
the controller with the connected oil volume. The switch is located behind the
screw on the housing cover of the VT-DFP pilot valve (see Fig. 29).
Switch positions 0 to 7 repeat themselves with the positions from 8 to F (see
table 5, center column).
For valve electronics with power controller with changeover feature (feature 12
in the type code is A; example: SYDFEE-2X/18R-PPA12N00-0000-A0A0FL1), a
second volume matching can be activated via the PLC switching input switch TD
(pin 9 / +24 V). This second matching is in a fixed relationship with the setting of
switch TD = 0 V as given in the right-hand column.

On valve electronics with other extra functions, pin 9 on the central plug-in
connector serves as switchable pressure controller for other functions.
f With this valve type, under no circumstances may an external voltage be
connected to this pin. This could lead to the destruction of the electronics
Table 5: Optimization of the pressure controller for SYDFEE (adjustment of the

coding switch)
Switch position 0 1 2 3 4 5 6 7 8 9 A B C D E F
TD OFF 5 6.25 7.5 10 12.5 15 20 25 5 6.25 7.5 10 12.5 15 20 25
1)
TD ON2) 7.5 10 12.5 15 20 25 30 35 12.5 15 20 25 30 35 40 45
1) Connected hydraulic fluid volume of lines and actuators (in liters)

2) For the second line (TD ON) exclusively variant A is relevant
Adjustment of the control loop
Connection cable to swivel angle transducer

Fig. 30: Optimization of the pressure controller
Example When optimizing the pressure controller you may find out that, for example, the
best setting for the actuator in question is reached with an oil volume of 10 l (that
is, optionally position -3- or, with switch TD OFF (0 V), -B-, see table 5).
If, however, the pump controls also other or more consumers, it is possible to
select a second adjustment via switching input switch TD ON (24 V) on the basis
of this setting (switch position S1 -3- or -B-).
Commissioning
If you select position -3- for switch S1, the volume adjustment of the controller can
be changed over to 15 l by activating switch TD (+24 V).
If you select position -B- for switch S1 you can change over to an even greater oil
volume (25 l) by activating switch TD (+24 V).
7.1.9 Adjusting the power limitation 1)

The power limitation feature can be used to determine the maximum power
consumption of the pump and thus protect the drive motor against overloading.
Example Calculation of the rated pump power

Motor power PM = 15 kW
Speed n = 1500 min-1
Displacement VG = 100 cm (pump size)
Maximum pressure pmax. = 200 bar
Efficiency mh = 1 (theoretical value)
Maximum pressure = pressure [bar], at which the actual pressure value output of
the valve (pin 8 of 11 + PE) provides +10 V.
VG [cm3] n [min-1] pmax [bar]

P100% = [kW]
600.000 mh
P100% = 78.75 kW
Calculation of the ratio
PM
(p )max = 100 % = 19 %
P100%
Select the operating pressure of the system.
10 V
pcomm= 250 bar = 7.94 V ( 79.4 %)
350 bar
In our example, it is 250 bar 7.94 V.

Calculation of the max. swivel angle with performance limit
(p )max = 19 % ( Pmax)
Pcomm [%] = 79.4 % ( 7.94 V)
(p )max 19 %
max = = 100 = 23.9 %
P 79.4 %
1)Only on version with optional function power limitation (type code feature 12 is B or
C - example: SYDFEE-2X/018R-PPA1200-0000-A0B1FL1).
Commissioning
7.1.10 Adjusting the constant power limitation with potentiometer R3

The power limitation can be set in two ways. Setting while the system is running
should be preferred.
R3: Adjustment of power limitation
Connection to swivel angle transducer
Fig. 31: Adjustment of power limitation
Adjustment while the system is running
For this method, you require:

an adjustable pressure relief valve as variable load for the pump
a measuring instrument for measuring the current consumption (or power
consumption) of the drive motor.
In the description below, we utilize the data of the example above.

1. Close all directional valves, i.e. no oil flow
2. Set the pressure relief valve (DB) slightly higher than the maximum pressure
(pmax = 250 bar; pDB = 270 bar)
3. Select the max. operating pressure (pmax = 250 bar) of the pump
4. Select a swivel angle command value greater than the calculated value
(comm > 3 V)
5. Slowly turn out the DB - the pump now displaces into the DB - and, at the
same time, measure the motor current (power); if it becomes too high, turn the
DB in immediately.
6. Vary the flow from the pump by means of the DB until the nominal motor
current flows; set the power limitation at this operating point.
7. Turn potentiometer R3 on the VT-DFPE-2X/... counter-clockwise until the
signal power limitation active is issued (= 24 V).
The signal power imitation active can be measured at central plug pin 9.
With the factory setting, potentiometer R3 is always set to maximum power

(100 %). In this case, the potentiometer is at the right-hand limit stop
position. To reduce the power limit, turn potentiometer R3 counter-clockwise.
Adjustment while the system is at a standstill
When making the adjustments while the drive motor is switched off, use the
calculated maximum power as a guideline.
1. Drive motor OFF
2. Selection of pressure command value >10 V, e.g. 10.5 V
3. Provision of actual pressure value at 10 (pact_High) and 11 (pact_Low) so that at
pin 8 (pact) +10V is measured.
4. Provide a swivel angle command value according to the desired power limit.
5. Turn R3 on the VT-DFPE-2X/... counter-clockwise until the signal power
limitation is issued (= 24 V). The signal power limitation active can be
measured at pin 9 of the central plug-in connector.
Commissioning
With the factory setting, potentiometer R3 is always set to maximum power

(100 %). In this case, the potentiometer is at the right-hand limit stop
position. To reduce the power limit, turn potentiometer R3 counter-clockwise.
7.1.11 Performing a functional test
WARNING! Risk of injury in case of incorrectly connected machine or system!

Any change of the connections will lead to malfunctions (e.g. lifting instead of
lowering) and thus represents a corresponding hazard to persons and equipment.
f When connecting hydraulic components, observe the specified piping
according to the hydraulic circuit diagram of the machine or system
manufacturer.
Once you have tested the hydraulic fluid supply, you must perform a functional
test on the machine or system. The functional test should be carried out according
to the instructions of the machine or system manufacturer.
Before delivery, the SY(H)DFEE control system is checked for functional

capability in accordance with the technical data. During commissioning, it must be
ensured that the SY(H)DFEE control system was installed in accordance with the
plans and drawings of the machine or system. Use the swivel angle indicator to
check whether the SY(H)DFEE control system swivels in and out correctly during
operation.
The position of the swivel angle indicator and the assignment of the swivel
direction to the direction of rotation and control can be found in the corresponding
technical data sheets.
7.1.12 Bleeding during commissioning or after longer standstill

periods
Just like during commissioning you have to bleed the SY(H)DFEE control system
also after longer periods of standstill in order that the pump can build up pressure
directly after the electric motor started up. The necessity for this depends,
however, also on the installation orientation of the pump.
You can bleed the system manually by opening the pressure line at a suitable
point (e.g. minimess port, valve, etc.). When an unloading valve to the tank is
installed (quasi pressureless start-up), this procedure can also be automated
when the electric motor starts up: The valve merely needs to be activated briefly;
a continuous pressureless start-up as described in the following is not required.
If a SYDZ pre-load valve is installed and the pump does not build up pressure
or displace hydraulic fluid, this valve must be bled additionally at point P as
described in section 7.1.5 Bleeding of the pre-load valve on page 54.
7.2 Recommissioning after standstill

Depending on the installation conditions and ambient conditions, changes may
occur in the system which make recommissioning necessary.
Among others, the following criteria may make recommissioning necessary:
Air in the hydraulic system
Water in the hydraulic system
Aged hydraulic fluid
Contamination
Operation
f For recomissioning, proceed as described in chapter 7.1 First commissioning

on page 52.
7.3 Running-in phase

Bearings and sliding surfaces are subject to a running-in phase. Increased friction
at the start of the running-in phase results in increased heat generation which
decreases with increasing operating hours. The volumetric and mechanical-
hydraulic efficiency rises as well by the end of the running-in phase of approx.
10 operating hours.
CAUTION! Risk of damage by insufficient viscosity!

The increased temperature of the hydraulic fluid during the running-in phase can
cause the viscosity to drop to impermissible levels.
f Monitor the operating temperature during the running-in phase.
f Reduce the loading (pressure, speed) of the SY(H)DFEE control system, if
impermissible operating temperatures and/or viscosities occur.
8 Operation
The product is a component which requires no settings or changes during
operation. For this reason, this chapter of the manual does not contain any
information on adjustment options. Only use the product within the performance
range provided in the technical data. The machine or system manufacturer is
responsible for the proper project planning of the hydraulic system and its control.
9 Maintenance and repair
9.1 Cleaning and care
CAUTION! Damage to the surface caused by solvents and aggressive detergents!

Aggressive detergents may damage the seals of the SY(H)DFEE control system
and cause them to age faster.
f Never use solvents or aggressive detergents.
CAUTION! Contaminants and fluids entering the system will cause faults!
This will result in the fact that the safe operation of the SY(H)DFEE control system
can no longer be ensured.
f When carrying out any work on the SY(H)DFEE control system observe
strictest cleanliness.
f Do not use high-pressure cleaners
For cleaning and care of the SY(H)DFEE control system, observe the following:
f Plug all openings with suitable protective caps/devices.
f Check whether all seals and plugs of the plug-in connections are securely
seated to ensure that no moisture can enter the SY(H)DFEE control system
during cleaning.
f Use only water and, if necessary, a mild detergent to clean the SY(H)DFEE
control system.
f Remove coarse dirt from the outside of the system and keep sensitive and
important components, such as solenoids, valves and displays, clean.
f Do not use high-pressure cleaners for cleaning the SY(H)DFEE control
system.
9.2 Inspection
In order that the SY(H)DFEE control system works reliably and for a long time,
Rexroth recommends that you inspect the SY(H)DFEE control system regularly
at the following maintenance intervals and document the following operating
conditions:
Table 6: Inspection schedule

Hydraulic system Check level of hydraulic fluid in the tank. Daily
Check operating temperature Weekly
(comparable load state).
Analyze quality of the hydraulic fluid. Annually or every
2000 h (whichever
occurs first)

SY(H)DFEE Inspect the SY(H)DFEE control system for Daily
control system leakage.
Early detection of hydraulic fluid loss can help
identify and rectify faults on the machine or
system. For this reason, Rexroth recommends
that the SY(H)DFEE control system and the
system as a whole always be kept in a clean
condition.
Check the SY(H)DFEE control system for Daily
generation of noise.
Check mounting elements for proper fit. Monthly
Inspect all mounting elements while the system
is switched off, depressurized and cooled down.
9.3 Maintenance
SY(H)DFEE control systems require little maintenance when used as intended.
The service life of the SY(H)DFEE control system is heavily dependent on the
quality of the hydraulic fluid. For this reason, we recommend changing the
hydraulic fluid at least once a year or every 2000 operating hours (whichever
occurs first) or having it analyzed by the hydraulic fluid supplier or a laboratory to
determine its suitability for further use.
The service life of the SY(H)DFEE control system is limited by the service life of
the built-in bearings. The service life can be requested on the basis of the load
cycle from the responsible Rexroth Service partner, see Chapter 9.5 Spare parts
below. Based on these details, a maintenance interval is to be determined by
the system manufacturer for the replacement of the bearings and included in the
maintenance schedule of the hydraulic system.
9.4 Repair
Rexroth offers a comprehensive range of services for the repair of Rexroth
SY(H)DFEE control systems.
Repairs of the SY(H)DFEE control system may only be performed by authorized,
skilled and instructed staff.
f Only use genuine spare parts from Rexroth for repairing Rexroth SY(H)DFEE
control systems.
Partially tested and pre-assembled original Rexroth assemblies allow for

successful repairs within a minimum of time.
9.5 Spare parts
CAUTION! Personal injury and damage to property due to wrong spare parts!
Spare parts that do not meet the technical requirements specified by Rexroth may
cause personal injury and damage property.
f Use only genuine spare parts from Rexroth.
When ordering spare parts, please indicate the material numbers of the relevant
spare parts. On some components, the material number is shown on a nameplate
or a label.
Please address all questions regarding spare parts to your responsible Rexroth
Service partner.
Bosch Rexroth AG
Service Hydraulics
Bgm.-Dr.-Nebel-Str. 8
97816 Lohr am Main
Tel: +49 (0) 9352 - 18-0
Fax: +49 (0) 9352 - 18-39 83
spareparts.bri@boschrexroth.de

f Please state the following data from the nameplate on your order:
material number
serial number
production job order number
production date
9.5.1 Replacement of components
CAUTION! Uncontrolled system behavior!

The failure of individual components can result in malfunction of the assembly!
f Replace or have defective components replaced immedately!
The replacement of some components of the SY(H)DFEE control systems is

described in the following.
Swivel angle sensor VT-SWA-1 for The operating principle of VT-SWA swivel angle sensors, which work with a Hall
SYDFEE systems sensor, is based on the evaluation of a magnetic field related to the rotary angle.
The system operates contactless and is therefore wear-free.
In case that repairs have to be carried out on the swivel angle transducer of the
SY(H)DFEE system, observe the installation notes for the VT-SWA swivel angle
sensor and its magnet carrier. The material number for the kit, magnet carrier and
seals included, is R900868651.
General
The magnet carrier is a sensitive component and must therefore be handled with
care. It must not be subjected to impacts and be kept away from magnetizable
or magnetic parts! Until the carrier is installed in the pump housing, the original
packaging is the safest place of storage.
In the case of pump assemblies that were produced before 10/97, a spacer
might have had to be installed under the magnet carrier for compensating for
differences in height. If the old swashplate is used, this spacer must be re-
installed. If new parts are used, the spacer is no longer required.
Installation of the magnet carrier

f Installation orientation with clockwise rotating pump:
The locating pin of the magnet carrier points towards the subplate of the pump
(away from the drive motor). The bore for the locating pin is marked with a
color point.
f Insert the magnet carrier in the receptacle provided in the housing of the A10
pump:
A special tool (plastic mounting sleeve, material no. R900846331) is required
for inserting and tightening the countersunk screw! If this mounting sleeve is
not available, use a suitable tool made of non-magnetic material for inserting
the mounting screw and for guiding a screw driver between the poles of the
magnet.
f Tighten the countersunk screw M6 x 12 to 10.5 Nm.
f After having installed the magnet carrier, check with your fingers, whether the
magnets positively adhere to the carrier.
Installation of rotary angle sensor VT-SWA-1-1X

f Glue in the O-ring of the kit in the groove using some grease.
f Tighten mounting screws M6 x 35 with washers to 15.5 Nm.
f Adjust the swivel angle sensor. Notes on the adjustment can be found in
Chapter 14.2.1 Checking the swivel angle measurement on page 74.
Miscellaneous
f If the magnet carrier must be removed, also use a suitable mounting sleeve
for loosening the countersunk screw (see note on Installation of the magnet
carrier).
If the rotary angle sensor fails, proper operation of the SY(H)DFEE system is no
longer possible.
Swivel angle sensor VT-SWA-LIN-1X General

for SYHDFEE systems The prod is a sensitive component and must therefore be handled with care. In
particular with regard to the magnetic properties, the prod must not be subjected
to hard impacts and must be kept away from metal parts! Keep the prod in the
original packaging until it is installed in the pump housing.
Installation of the rotary angle sensor VT-SWA-LIN-1X

f Tighten sensor to 25 +5 Nm (27 A/F)
f Adjust the swivel angle sensor. Notes on the adjustment can be found in
Chapter 14.2.1 Checking the swivel angle measurement on page 74.
f Measure the actual swivel angle value and set it to 10.05 V +0.01 V
(corresponds to maximum stroke) using potentiometer G.
f In some cases, the pump will not swivel out to the positive stop. For this
reason, switch the motor on briefly, then switch off, wait until the pump has
swiveled out and then measure the actual swivel angle value. If a higher
voltage is measured, correct the value. Repeat this procedure several times.
Seal kits for the pump Stating the Mat. no. of the pump you can order seal kits, which are either tailored
to the individual component or grouped in a complete package.
Pilot valve VT-DFPE-x-2X The pilot valve is a component, which is sensitive to contamination. When
replacing it, take care that no contaminants can enter fluid-carrying parts of the
valve and the pump. To replace the pilot valve loosen the 4 screws at the
recessed corners of the nameplate on the pilot valve. After the replacement,
tighten the screws to a tightening torque of 7 Nm 10 %. Newly installed valves
with integrated electronics need to be adjusted:
f Take the parameter setting of the coding switch over from the demounted
valve.
f Check the calibration of the actual pressure value and, if required, readjust as
described on page 56.
f Check/calibrate the actual swivel angle value on the VT-SWA-1X, see
page 74.
Pre-load valve SYDZ0001 To replace the pre-load valve, loosen the mounting screws and remove the
pre-load valve.
Mounting screws
Fig. 32: Mounting bores: left-hand side (round) for NG18, 28, 25; right-hand side
(rectangular) for NG 71, 100, 140
When positioning a new pre-load valve, take care that the seal on the pump side
to the pre-load valve is located in the recess provided for this purpose. Tighten
the mounting screws to the following torque:
Sizes 18, 28 und 45: 45 Nm
Size 71: 55 Nm
Sizes 100 and 140: 100 Nm
After having mounted the pre-load valve, connect the pipes for high pressure
and case drain oil as described in chapter 6.3 Installation positions and piping of
SY(H)DFEE systems. During re-commissioning, bleed the pre-load valve. Notes
on the bleeding procedure can be found in Chapter 7.1.5 Bleeding the pre-load
valve on page 54.
HM16-1X Disconnect the electrical connection on the pilot valve. Replace the pressure
transducer by turning out the existing pressure transducer and screwing in a new
one. Tighten the pressure transducer to a torque of 15 Nm.
9.5.2 Test devices, assembly tools and note on commissioning

Test box for SYDFEE und SYDFEC We offer a hand-held control box, designation VT-PDFE-1-1X/V0/V0 (Mat. no.
R900757051) for control systems SY(H)DFEE, SY(H)DFEC and SY(H)DFEn for
looping in into the existing cabling.
The hand-held control box requires a 24 V voltage supply from the customer side
for the internal reference voltage and is equipeed with:
Command value potentiometer for swivel angle and pressure
Measuring points for all connection pins
Additional supply option for a pressure transducer
Fitting tool for VT-SWA-1 swivel The following fitting tool is available for the magnet carrier:
angle transducer (Hall sensor)
For mounting: Installation aid for carrier of VT-SWA, Mat. no. R900846331
for SYDFEE-/2X, SYDFEC-2X and
SYDFEn
Decommissioning
10 Decommissioning
The SY(H)DFEE control system is a component that does not require
decommissioning. For this reason, this chapter of the present instructions does
not contain any information.
For details about how to disassemble or replace your SY(H)DFEE control system,
please refer to Chapter 11 Demounting and replacement below.
11 Demounting and replacement
11.1 Required tools

Disassembly can be performed with standard tools. No special tools are
necessary.
11.2 Preparing demounting
WARNING! Risk of injuries due to demounting under pressure and voltage!

If you do not switch off the pressure and power supply before demounting
the product, you may get injured or the device or system components may be
damaged.
f Make sure that the relevant system components are not under pressure or
voltage.
1. Decommission the entire system as described in the general instructions for

2. Depressurize the hydraulic system according to the instructions of the
machine or system manufacturer.
11.3 Demounting the SY(HDFEE control system

Proceed as follows to demount the SY(H)DFEE control system:
1. Make sure that the hydraulic system is depressurized.
2. Check that the SY(H)DFEE control system has cooled down sufficiently so
that it can be uninstalled without any risks.
3. Place a catch pan under the SY(H)DFEE control system to collect any
hydraulic fluid that may escape.
CAUTION! Danger of environmental pollution!

The discharge or spillage of hydraulic fluid while filling the SY(H)DFEE control
system can lead to environmental pollution and contamination of the groundwater.
f When filling and changing the hydraulic fluid, always place a catch pan under
f Observe the information in the safety data sheet for the hydraulic fluid and the
specifications provided by the system manufacturer.
Disposal
1. Loosen the lines and collect the escaping hydraulic fluid in the collector
2. Remove the SY(H)DFEE control system. Use suitable lifting gear for this.
3. Drain the SY(H)DFEE control system completely.
4. Plug all openings.
11.4 Preparing the components for storage or further

use
f Proceed as described in Chapter 5.2 Storing the SY(H)DFEE control system
on page 34.
12 Disposal
12.1 Environmental protection

Careless disposal of the SY(H)DFEE control system, the hydraulic fluid and the
packaging material could lead to pollution of the environment.
f Therefore, dispose of the SY(H)DFEE control system, the hydraulic fluid and
the packaging material in accordance with the currently applicable regulations
in your country.
f Dispose of hydraulic fluid residues according to the applicable safety data
sheets for these hydraulic fluids.
12.2 Return to Bosch Rexroth

Products manufactured by us can be returned to us free of charge for disposal.
However, a precondition is that the products are free from any deposits or other
contaminations. Hydraulic products must be drained before being returned.
Moreover, the products must not contain any unacceptable foreing particles or
components of other make.
Please return the products free domicile to the following address:
Bosch Rexroth AG
Brgermeister-Dr.-Nebel-Strae 8
97816 Lohr am Main
Deutschland
12.3 Packaging
For regular deliveries we can use re-usable systems. The materials used for
disposable packagins are mainly cardboard, wood and styrol. These can be
recycled without any problems. However, for ecological reasons, the use of
disposable packagings should be avoided for return shipments to us.
Extension and conversion
12.4 Materials used

Our products do not contain any hazardous substances that could be realeased
during proper use. In normal cases, no negative effects on man and environment
have to be expected.
The products basically consist of:
Cast iron
Steel
Aluminum
Copper
Plastics
Electronic components and assemblies
Elastomers
12.5 Recycling
Due to the large metal content our products can be recycled to a great extent.
To ensure optimum metal recycling, the units must be disassembled to obtain
individual assemblies. Metals contained in the electrical and electronic assemblies
can also be recycled using specific separating procedures. As far as products
contain any batteries, these must be removed prior to the product recycling and
should be recycled as well whenever possible.
13 Extension and conversion

The SY(H)DFEE control system may only be converted or extended in the
cases described below using genuine Rexroth SY(H)DFEE components. Other
conversions or extensions, also the readjustment of lead-sealed adjustment
potentiometers render the warranty void. The replacement of a component with
a component of the identical design is described in Chapter 9.5 Spare parts on
page 63.
An extension by adding a SYDZ pre-load valve is possible on the SYDFEE control
system, but not on the SYHDFEE control system. Please ensure that the size of
the pre-load valve and the size of the pump are identical. If the control system is
provided with an HM16 pressure transducer at the valve ex factory, the pressure
transducer must be removed and re-mounted to the pre-load valve, because the
pressure at the pump and the pressure in pressure port P1 of the pre-load valve
may be different.
If an HM 16 pressure transducer is mounted on the pre-load valve or the pump
of the control system, the pressure transducer can be removed and re-mounted
at another position within the system. In this case, the connection for the
pressure transducer must be plugged with a plug, which is suitable for high
pressure applications. For the installation, observe the notes given in Chapter
6.6.3 Selection, place of installation and mounting orientation of the pressure
transducer on page 48.
Troubleshooting
14 Troubleshooting
The following table may assist you in troubleshooting. The table is not exhaustive.
In practice, problems which are not listed here may also occur.
14.1 How to proceed for troubleshooting

f Always act systematically and targeted, even under pressure of time. Random
and imprudent disassembly and readjustment of settings might result in the
inability to ascertain the original cause of fault.
f First obtain a general overview of how your product works in conjunction with
the entire system.
f Try to determine whether the product worked properly in conjunction with the
entire system before the troubles occurred.
f Try to determine any changes of the entire system in which the product is
integrated:
Were there any changes to the products operating conditions or operating
range?
Were there any changes or repairs on the complete system (machine /
system, electrics, control) or on the product? If yes, which?
Was the product or machine used as intended?
How did the malfunction manifest itself?
f Try to get a clear idea of the error cause. Directly ask the (machine) operator.
f If you cannot rectify the error, contact one of the contact addresses which can
be found at:
Troubleshooting
14.2 Malfunction table

Table 7: Malfunction table for SY(H)DFEE control systems
Error output (X1, Pin 3) is 0-5 V Error in the actual pressure value branch Test actual pressure value signal (X1, pin 10
Diagnosis: Actual pressure value normalized and 11) (wire rupture, working range, signal
(X1, pin 8) is less than -0.5 V or greater than type, polarity)
11.5 V
Error in the actual swivel angle value branch Check wiring and function of the swivel angle
Diagnosis: Actual swivel angle value normalized transducer (see page 74)
(X1, pin 6) is less than -11.5 V or greater than
+11.5 V
Excessive control error of the pressure and Adjust the command values for pressure and
swivel angle controller swivel angle to the actual values (e.g. 0 bar /
+100 %) while the drive motor is switched off
Temperature limit value exceeded in the Reduce ambient temperature to below 60 C,
housing (ca. 80 C) increase air movement in the surroundings
Actual valve value less than -11.5 V or greater Contact Rexroth Service
than +11.5 V
Voltage symmetry of internal voltages of the Contact Rexroth Service
pilot valve outside the limit value
Humming noise in the pressure control Air cushion around the sensor Bleed control system, pre-load valve (see page
or fluctuations in pressure / flow 54) and pipes completely
Problem with the cable shield Ground shield
No connection from M0 to L0 Connect M0 (X1, pin 4) and L0 (X1, pin 2) in the

control cabinet
Unfavorable place of mounting / mounting Change place of installation (e.g. suspended
technique of the pressure transducer mounting, no minimess line, no throttling point
between pump and pressure transducer)
Unsuitably high gain of the actual pressure Reduce weighting of the actual pressure value
value and pressure command value, see page 56
Screaming noise Oil level in the tank too low; pump partly aspires Top up oil
air
Pump aspires air Change the routing of the suction line
Suction line leaky Seal suction line
Pump cavitates when pressure is reduced Optimize controller, reduce the command value
Diagnosis: Measure, whether the pressure in via a ramp or in steps.
the pressure line overshoots
Fluid in the tank mixed with air; cooling and/or Seal
filtration circuit leaky
Troubleshooting

Other unusual noise Input speed too high Machine or system manufacturer
Wrong direction of rotation Machine or system manufacturer
Insufficient suction conditions, e.g. air in the Check, whether shut-off valves are open
suction line, insufficient diameter of the suction
line, viscosity of the hydraulic fluid too high, Machine or system manufacturer (e.g. optimize
suction height too great, suction pressure too inlet conditions, use suitable hydraulic fluid)
low, foreign body in the suction line Completely air-bleed control system, fill suction
line with hydraulic fluid
Remove foreign body from the suction line
Improper mounting of the control system. Check mounting of the control system according
to the instructions given by the machine or system
manufacturer. Observe tightening torques.
Improper mounting of connected parts, e.g. Mount attachments in accordance with
coupling and hydraulic lines the instructions of the coupling or fitting
manufacturer
Air in the pump or in the pre-load valve Bleed pump and pre-load valve
Wear of / mechanical damage to the control Replace control system, contact Rexroth
system Service
No or insufficient pressure (< 4 bar) Faulty mechanical drive (e.g. defective coupling) Machine or system manufacturer
Hydraulic fluid not within the optimum viscosity Use suitable hydraulic fluid (machine or system
range manufacturer)
Drive unit defective (e.g. hydraulic motor or Machine or system manufacturer
cylinder)
Wear / mechanical damage Replace control system, contact Rexroth
Service
Pressure fixed, ca. 5...12 bar, cannot Supply voltage not within the permissble range Check, whether central plug-in connector X1 is
be changed (23...33.6 V) connected to the pilot valve
Diagnosis: Is the actual swivel angle value
(X1, pin 6) 0 Volt? If yes, is the supply voltage Check voltage at the last interconnection point
missing? (terminal strip) before the pilot valve
Command vaue for pressure, swivel angle or If you utilize, for example, only closed-loop
power (optional) is 0 bar or 0 %, respectively pressure control, connect the swivel angle
command value (X1, pin 5) to +10 V
The potentiometer for the (optional) power
limitation must not be at the left-hand limit stop
Swivel angle sensor defective Inspect swivel angle sensor, see page 74
Spool jams in pilot valve Contact Rexroth Service

Troubleshooting

Pressure too low ( < 12 bar) Evaluation of the actual pressure value is Adjust pressure command value and/or actual
incorrectly set pressure value (see 7.1.6)
Diagnosis: Pressure command value (X1, pin 7)
and actual pressure value normalized (X1, pin
8) are equal and can be controlled Change place of installation of the pressure
transducer (do not install upstream of the pre-
load valve, rather close to the consumer)
Pressure transducer defective / not connected Replace pressure transducer
Diagnosis: Measure signal from pressure
transducer and compare with indication on the
pressure gauge
Control system does not work in closed-loop Increase swivel angle command value
pressure control
Increase power limit (see page 58)
normalized is less than actual value (X1, pin 8) Check, whether hydraulic system is leak-free
normalized and the consumption is not too great .
Pilot valve defective Replace pilot valve
Pressure too high Evaluation of the actual pressure value is Adjust pressure command value and/or actual
and actual pressure normalized (X1, pin 8) are Replace pressure transducer
equal and can be controlled
Replace pilot valve, see page 65
Pressure transducer (PT) defective / not Replace pilot valve, see page 65
connected
Diagnosis: Measure signal from PT and
compare with indication on the pressure gauge
Flow too small Pressure controller active Increase pressure command value
Power limitation (optional) active. Increase power command value (optional) (see
page 59)
Actual swivel angle acquisition maladjusted Adjust swivel angle sensor (see page 75)
Speed of drive too low (slip, incorrect frequency, Machine or system manufacturer
wrong motor)
Pump damaged (pump leakage too great) Rotary group defective
Wear / mechanical damage to the control Replace control system, contact Rexroth
system Service.
Drive motor switches off due to Excessive power consumption of the pump Reduce power command values (optional (see
overloading page 58)
Reduce swivel angle command value
Test actual pressure value acquisition (see
page 56)
Protective overcurrent feature of the motor does Check setting and test function
not work properly
Spool jams in pilot valve Replace pilot valve, see page 65
Diagnosis: Disconnect central plug-in connector X1
or supply voltage from pilot valve and test whether
the motor is still overloaded
Actual swivel value acquisition maladjusted or Check actual swivel angle acquisition, see page
does not work 74
Valve electronics defective Replace pilot valve, see page 65
Troubleshooting

Hydraulic fluid temperature too high Inlet temperature at control system too high Inspect system, e.g. malfunction of cooler,
insufficient hydraulic fluid in the tank
Pre-load valve opens Pressure must be lower than cracking pressure
Diagnosis: Pipe to the tank heats up of pre-load valve. Keep overshoots and
pressure pulsations to a minimum
Malfunction of pressure control valves (e.g. high Contact Rexroth Service.
pressure relief valve, pressure cut-off valve,
pressure controller)
Control system worn out Replace control system, contact Rexroth
Service
14.2.1 Checking the swivel angle measurement

The settings for swivel angle measurement are made in the factory. The settings
described below are only required after a replacement of the swivel angle
transducer.
Depending on circumstances, a calibration of the swivel angle 100 % can be
conducted while the drive motor is running or at rest.
Checking swivel angle zero (while system is running)
Close all directional valves

Apply a swivel angle command value of >5 V
Apply a pressure command value of 20 bar
Check, whether the actual swivel angle value (act) is 0 V 100 mV
In the case of deviations, correct by means of potentiometer (1); the
potentiometer is marked with O (= Offset)
Checking swivel angle 100% (while system is running)
Swivel angle command value greater than 10.5 V, pressure command value ca.
5V
Direct the full flow via the actuator, e.g. activate hydraulic motor or set pressure
relief valve to ca. 20 bar; in this case, the pilot valve deliberately signals an
error (control deviation too great)
Adjust potentiometer (2) until the actual swivel angle value is +10.05 V; the
potentiometer is marked with G (= gain) on the swivel angle transducer
(corresponds to maximum stroke).
Checking swivel angle 100% (while drive motor is switched

off)
Switch the hydraulic system off and wait for ca. 5 min until the pump has
swiveled out mechanically (wait until pressure has decreased completely).
Turn potentiometer (2) until the actual swivel angle value is +10.05 V; the
potentiometer is marked with G (= gain) on the swivel angle transducer.
In some cases, the pump will not swivel out to the positive stop. For this reason,
switch the motor on briefly, then switch it off again and wait until the pump
has swiveled out. Measure the actual swivel angle value. If a higher voltage is
obtained, correct the value.
Repeat this process several times!
Technical data
Fig. 33: Swingle angle sensor for SYDFEE
1
O

2
G
Fig. 34: Swingle angle sensor for SYHDFEE
1 Zero point adjustment of swivel angle

2 Setting of max. swivel angle
15 Technical data
The technical data of your SY(H)DFEF system are contained in the following data
sheets:
SYDFEE series 2X RE 30030
SYDFEE series 3X RE 30630
SYHDFEE series 1X RE 30035
The data sheet can be found on the Internet at
www.boschrexroth.com/ics
The preset technical data of your SY(H)DFEE control system can be found in the
order confirmation.
Annex
16 Annex
16.1 Address directory

For the addresses of our foreign subsidiaries and responsible sales companies,
please visit http://www.boschrexroth.com.
Contact for repairs and spare parts
Bosch Rexroth AG
Brgermeister.-Dr. Nebel-Str. 8
97816 Lohr am Main
Germany
Our spare parts catalog can be found on the Internet at

http://www.boschrexroth.com/spc
Here you can find also your technical contact
Contacts for repairs are listed on the Internet at:

http://www.boschrexroth.com/service
Ordering address for accessories and valves
Headquarters:
Bosch Rexroth AG
Hydraulics
Zum Eisengieer 1
97816 Lohr am Main
Germany
Phone +49 (93 52) 18-0
or the relevant sales subsidiary.
Addresses can be found on the Internet at:
http://www.boschrexroth.com

L0 L0 Switch TD 1)
1 xSWA < xp
Switch TD 1) or power
9 &
limitation active 1 SWAmax < SWAcomm
0F + UB
pcomm 0 to +10 V 7 xp
U PD MIN PD U
U L0 x I
Pressure
1 controller x
ULP R2
2) 4
HM16 P
U R3 U
3 L0 v
16.2 Block circuit diagram
(p ) max SWA = (p SWA)max

pact 4 to 20 mA H 10 max > + 3,3 V
U(i) pact
or 0 to +10 V 11 < 3,3 V
L U L0 =
0 to 5 V, 1 to 10 V DIV
max
8
pact 0 to +10 V U =
U L0
SWAcomm 0 (-10) to +10 V 5

U MIN P t = 1s
M0 4 U L0
RE 30012-B/09.10 | SYDFEE series 2X, 3X, SYHDFEE series 1X
U 10 V 5V3V 2
SWAact -10 V to +10 V 6 U L0 3
10 V
In the control > + 11,5 V > + 11,5 V Cable break > 80 C 1
< 0,5 V < 11,5 V L0
cabinet: Bridge 4
between pin 2
and 4
Swivel angle
1 acquisition
Fault signal ( 0 V) 3
ULP
+UB 1 10 V
U + 15 V
L0 2 U 15 V
L0
PE
Bosch Rexroth AG
--- Only with variant with optional power limitation function (ordering code B)
1) Switch TD only with variant without optional power limitation function (ordering code A)
2) Variant F only
Annex
77/80
Alphabetical index
17 Alphabetical index
A F
Abbreviations 6 Filling 52
Activation sequence 31 Filtration 24
Actual pressure value adjustment 56 Flushing cycle 53
Actuating system supply 13 Functional description 12
Address directory 76 Functional test 60
Adjusting
constant power limitation 59
G
Adjusting the power limitation 58
Adjustment work 55 Generation of noise 25
Ambient conditions 22
Ambient temperature 22 H
Assembly tools 66
HFC fluids 24
HM12 50
B HM13 50
Basic operating modes 15
Bleeding 60 I
Bleeding the pre-load valve 54
Identification of the product 31
Brief regenerative operation 19
Improper use 7
Inspection 62
C Inspection schedule 62
Cabling 47 Installation 36
Care 62 with coupling 41
Case drain oil compensation 27 Installation conditions 36
Case drain piping 39 Installation drawing 5
Caution 8 Installation positions 37
Checking 74 Installing the SY(H)DFEE control
swivel angle 100% 74 system 40
swivel angle measurement 74 Intended use 7
swivel angle zero 74 Internal pilot oil supply 21
Circulation operation 17
Cleaning 62 K
Commissioning 51
Keyed shaft 25
first 52
Connecting
electrically 46 M
hydraulically 43 Maintenance 62, 63
Controller structure 15 Malfunction table 71
Conversion 69 Master/slave operation 28
Maximum system pressure 20
D Minimum system pressure 21
Danger 8
Data sheet 5 N
Decommissioning 67 Nameplate 31
Delivery contents 11 Noise level 24
Demounting 67
Device description 12
Dimensions 32 O
Direction of rotation 41 Obligations 10
Disposal 68 Oil-immersed applications 22
Dmensioning 22 Open circuit 12
Operating pressure
Limits 20
E maximum 20
Environmental protection 68 Minimum 21
Extension 69 Operating viscosity 23
External pilot oil supply 21 Operation 61
Optimizing the pressure controller 57
Alphabetical index
Order confirmation 5 Switching on

Ordering address 76 drive motor of the pump 54
supply voltage for the electronics 53
Swivel angle adjustment 14
P
Swivel angle control 15
Packaging 68
Performance description 12
Pilot oil 21 T
external 21 Technical data 75
internal 21 Temperature range 23
Piping 37, 38 Test devices 66
Power limitation 16, 27 Testing the hydraulic fluid supply 55
Power supply 47 Tightening torques 45
VT-DFPE pilot valve 47 Transport 32
Pre-load valve 21 Troubleshooting 70
Preparation 40
U
56
Pressure control 16 Unpacking 36
closed-loop 16
Pressure controller with changeover V
feature 26
Viscosity limits 23
Pressure transducer
mounting orientation 48
place of installation 48 W
selection 48 Warning 8
Product description 12 Warranty 9
Pulsation damper 25 Weights 32
Q Z
Qualifications 7 Zero stroke operation 17
Zero stroke pressure 14
R
Recommissioning 60
after downtime 60
Regenerative operation 18
brief 19
continuous 18
Related documents 5
Repair 63
Replacement 67
Replacement of components 64
Return 68
Routing of lines 43
Running-in 61
S
Safety instructions 7, 8
Seal kits 65
Section 12
Shaft version 25
Spare parts 63
Special operating modes 17
Splined shaft 26
Spool variant 26
Stand-by operation 17
Starting up at zero pressure 17
Storage 32
Storing 34
Bosch Rexroth AG
Hydraulics
Zum Eisengieer 1
97814 Lohr a. Main, Deutschland
Phone +49 (0) 93 52/18-0
Fax +49 (0) 03 52/18-2358
documentation@boschrexroth.de
www.boschrexroth.com
Printed in Germany
RE 30012-B/09.10

Valvula VT-DFPE PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Valvula VT-DFPE PDF

Загружено:

Авторское право:

Доступные форматы

Industrial Hydraulics FAQs

FAQ Title: VT-DFP(E) Identification

After pilot replacement, the pump should be calibrated. See commissioning

direct operated, with electrical

Type VT-DFP-.-2X/... with mating Type VT-DFPE-.-2X/... with integrated

Table of contents Features

4 Direct voltage 24 V G24

5 Connector (without mating connector) 1) K0

Additional functions: Closed-loop control A B C D R

Actual pressure value input Plug-in connector

11 Further details in plain text, e.g. SO variant

Note on feature 6: Installation orientation of the valve electronics

V T- D F P E - A - 2 2 / G 2 4 K 0 / 0 A 0 E / V 4 Production order number

Ordering code: Accessories

Version 10/2011, enquire availability

Accessories for VT-DFP Material number Data sheet

Electrical connection: Type VT-DFP... (for external analog electronics)

Inductive position transducer

Electrical connection: VT-DFPE... (with integrated analog electronics)

Allocation of connector or mating connector and cable set

X2: Connection of pressure transducer HM 16 (mating connector M12)

Electrical connection: VT-DFPC... (with integrated digital electronics)

Allocation of connector or mating connector and cable set

Electrical connection: VT-DFPn... (with integrated digital electronics)

Electrical connection: VT-DFPn... (continued)

Unit dimensions (dimensions in mm)

Required surface quality of

Item explanation see page 12

Unit dimensions (dimensions in mm)

Type VT-DFPC...2X/... and VT-DFPn...2X/...

1 Valve housing 13 Dimension for version VT-DFPE...F, VT-DFPC

Project planning information

More information on control systems SY(H)DFE

Operating instructions for SY(H)DFE1 30011-B

SYDFE1, series 2X SYDFE1, series 3X VT 5041-3X

Valid for the following types:

This document, as well as the data,

An example configuration is shown on the title

The original operating instructions were created in

About this document

1 About this document

1.1 Validity of the documentation

This documentation is intended for engineers, fitters, operators, service

1.2 Required and supplementary documents

Table 1: Required and supplementary documents

About this document

Title Document no. Type of document

1.3 Representation of information

1.3.1 Safety notes

Warning symbol: draws attention to a hazard

About this document

Table 2: Hazard classes according to ANSI Z535.6-2006

NOTICE Damage to property: The product or the environment

ff Single, independent step of action

1.3.3 Terms used

About this document

1.3.4 Abbreviations used

2.1 About this chapter

2.2 Intended use

2.3 Improper use

2.4 Personnel qualifications

2.5 General safety instructions

2.6 Product- and technology-related safety instructions