Hydraulic Systems

High-Flow Just Got Smarter: Inside the New CytroPac 2X Small Hydraulic Power

You spoke, we engineered. How direct customer feedback shaped the next evolution of compact, intelligent hydraulics.

When Bosch Rexroth introduced the original CytroPac, it fundamentally challenged what a hydraulic power unit had to look like. It eliminated sprawling, leaky 100-liter oil tanks, silenced shrieking pumps, and integrated the variable-frequency drive right on top of the power unit.

It quickly became the benchmark for machine tools and compact industrial automation. But at Bosch Rexroth, being an industry standard is just the baseline.

Over thousands of operational hours on shop floors worldwide, machine builders and maintenance managers gave us clear feedback on how to make CytroPac even better:

  • “We love the compact footprint, but we need more modularity to mount our own valves and handle large return flows.”
  • “Give us industrial-grade connectivity and continuous condition monitoring.”
  • “Help us cut energy consumption and CO₂ even further.”
  • “Make setup, maintenance, and visual diagnostics simpler for operators on the floor.”

The result is the CytroPac Series 2X—a power unit perfected by you.

Here is a closer look at what’s new in the 2X evolution and what it means for your machines.

Modularity That Fits Your Circuit, Not Ours

In the past, integrating directional or proportional control into a compact hydraulic circuit often meant mounting an external manifold block nearby, running extra hoses, and wasting valuable floor space.

The CytroPac 2X solves this with pre-engineered, factory-matched Functional Modules:

  • Standard Return Filter Module (M1): 10 µm filtration with integrated cold-start suppression monitoring to prevent false clogging alarms when oil is cold.
  • Leakage Oil Module (M2): Dedicated dual-return routing with built-in diffusers for pressure-free return of large volume flows, preventing oil foaming and aeration.
  • Valve Module (M3): An integrated NG6 (ISO 4401-03-02-05) interface plate mounted directly onto the power unit. You can now bolt standard Rexroth directional valves or multi-station manifolds straight onto the CytroPac.
  • Filter Module with DBV (M4): Integrated system pressure relief directly combined with the return filter.

Whether you need a standalone pressure supply or a complete, self-contained hydraulic control station, the 2X configures to your exact footprint.

Up to 80% Energy Savings: The Math Behind the Machine

Energy costs and carbon reduction mandates are no longer abstract targets—they directly impact operational margins.

The CytroPac 2X pairs high-efficiency motor options (including an IE5 PMSM servo motor on the 4.0 kW model and an IE4 asynchronous motor on the 2.2 kW model) with Bosch Rexroth’s Sytronix variable-speed pump drive.

Instead of running a fixed-speed motor that constantly dumps unused oil over a relief valve at high pressure, CytroPac 2X dynamically matches pump speed to the exact flow and pressure the cycle demands. In holding-pressure or idle phases, the motor slows down or drops into an intelligent sleep mode, slashing energy consumption by up to 80%.

The CytroPac 2X

Big Cooling Power in a Tiny 20-Liter Tank

How do you run 280 bar pressure and up to 38.5 l/min of flow out of a unit with only a 20-liter oil tank?

Traditional hydraulics rely on a massive 60 to 100-liter reservoir simply to let trapped air bubbles escape and allow oil to cool down before being drawn back into the pump. CytroPac eliminates this bulk using two patented innovations:

  • Degassing-Optimized Tank Flow: CFD-designed internal geometries guide returning fluid along precise paths that de-aerate oil almost instantly.
  • Heat Pipe Cooling Technology: Heat pipes transfer up to 2 kW of heat away from both the submerged motor/pump assembly and the oil reservoir straight into a heavy-duty aluminum cooling plate.

The result? 80% less hydraulic fluid to buy and dispose of, a 50% smaller machine footprint (1,200 cm² vs. 2,400 cm²), and an enclosure that completely muffles pump noise—operating at conversational sound levels even under full load.

Native Connectivity: Smarter Monitoring, Zero Hassle

Gone are the fragile RJ45 and Push-Pull connections of earlier units. The CytroPac 2X standardizes on rugged M12 Multi-Ethernet connectors, allowing seamless integration into fieldbus networks (Profinet, EtherCAT, Ethernet/IP, and Sercos).

The integrated frequency converter acts as an edge sensor node. In addition to standard digital switches, the 2X offers continuous 0–100% oil level sensing and 0–60°C continuous temperature logging. Connected to CytroConnect Solutions, your maintenance team can predict filter clogging, track thermal performance, and plan component servicing long before unexpected downtime occurs.

And for operators on the floor:

  • A bright Status LED bar integrated directly into the top hood provides immediate visual status from any viewing angle.
  • An optional 4.3″ HMI Touch Display right on the housing gives technicians instant readout of operating pressure, oil temperature, motor speed, and active alarms.
  • Our Commissioning Wizard gets the unit running in minutes via the USB service interface.

Designed for Global Deployment

For machine builders exporting to North America, regulatory certifications can be a costly bottleneck. The CytroPac 2X features optional cULus listing complete with an industrial-grade steel hood, alongside integrated Safe Torque Off (STO SIL 3 / PL e). You can specify one global design, confident that it meets electrical and mechanical safety standards anywhere in the world.

The Bottom Line

The CytroPac 2X proves that component evolution doesn’t happen in a vacuum—it happens when engineers listen to the people running the machines every day.

  • More modularity for custom control circuits.
  • More connectivity for Industry 4.0 monitoring.
  • More energy efficiency to cut your power bills and carbon footprint.
  • More simplicity for the technicians on your shop floor.

Ready to see how much energy and space you can save on your next machine build? Connect with your local Bosch Rexroth representative or explore the full datasheet at www.boschrexroth.com/cytropac.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Your VFD Solution is Here: Why Pre-Engineered is Smarter Engineering

In the world of hydraulic power unit design, customization often feels like the only path. You select a drive, size an enclosure, source the components, and manage the panel wiring and integration. This “engineered-to-order” (ETO) process provides ultimate flexibility, but it comes at a cost: long lead times, complex quoting, and significant engineering overhead.

But what if your application uses a standard variable displacement or fixed displacement pump? What if you need the proven energy savings of a variable frequency drive (VFD) without the ETO timeline?

This is where smarter engineering prevails. Introducing the Bosch Rexroth CytroCab, a pre-engineered packaging program that puts our industry-leading Sytronix VFD technology into a standardized, ready-to-integrate cabinet. It’s the fastest way to bring intelligent, efficient hydraulic power to your machine.

Standardization: Your Competitive Advantage

The core idea behind the CytroCab is simple: by pre-engineering the most requested drive configurations and options, we can dramatically shorten delivery times and simplify the entire procurement process.

Instead of starting from a blank sheet, you start with a proven, reliable base configuration:

  • A Bosch Rexroth EFC 5610 Variable Frequency Drive
  • Industry-leading Sytronix pump control software
  • A rugged, NEMA 12-rated enclosure
  • Fused circuit protection (upgradable to fused disconnect)
  • Thermostatically controlled cooling

This isn’t a limitation; it’s an accelerator. It removes the variables and guesswork from panel design, allowing you to get standard pricing and faster delivery, moving your project forward with confidence and speed.

The Power of Sytronix: More Than Just a Drive

At the heart of every CytroCab is our Sytronix control software, a specialized firmware designed to unlock the full potential of your hydraulic system. When paired with a Bosch Rexroth pump, Sytronix isn’t just spinning a motor; it’s intelligently managing power.

Massive Energy Savings: Sytronix automatically reduces motor speed during low-flow or no-flow periods, slashing energy consumption compared to traditional, fixed-speed power units.

Reduced Noise: Lower average motor speeds mean a quieter machine and a more comfortable, productive work environment.

Longer Component Life: Reduced wear on the motor and pump bearings leads to increased uptime and a lower total cost of ownership.

Intelligent Pump Protection: With features like leakage and thermal detection, Sytronix actively protects your pump, enhancing the reliability of your entire system.

Configured for Your Needs

Starting with the base model, the CytroCab offers a focused set of powerful options to tailor the solution to your specific machine requirements. Need local start/stop controls and status lights? The Local Control Kit (LC) adds them directly to the door. Need to monitor HPU sensors or add advanced supervisory functions? The PU option is designed for it.

For modern, connected machinery, the Ethernet Communication Kit (EC) provides a direct link to your plant-wide network, supporting protocols like Ethernet/IP, Profinet, and EtherCAT.

The Smart Choice for Efficient Hydraulics

The CytroCab is the ideal solution for end-users, machine builders and system integrators who need the benefits of a VFD without the cost and complexity of a full ETO build. It combines the reliability of Rexroth components, the intelligence of Sytronix software, and the speed of a standardized, pre-engineered solution.

Stop re-engineering the wheel. Move your project forward faster with the CytroCab.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

The Hidden Cost of “Always On” Hydraulics—And How to Fix It

Your hydraulic pump is working hard right now. Even when your machine isn’t.

If you’re running fixed displacement pumps, they’re delivering full flow every moment they’re spinning—whether your system needs 100% capacity or 10%. It’s like driving with your foot on the gas and using only the brake to control speed. It works, but it’s incredibly wasteful.

The Energy Waste Problem Nobody Talks About

Here’s what most plant managers don’t realize: a typical fixed displacement hydraulic system wastes 30-40% of its input energy during normal operation. That energy doesn’t just disappear—it becomes heat that your cooling system has to remove, creating a double cost.

Let’s put numbers to it. A 50 HP hydraulic power unit running two shifts (4,000 hours/year) at $0.12/kWh costs roughly $18,000 annually to operate. If 35% of that is waste, you’re literally throwing away over $6,000 per year, per machine.

Multiply that across your facility.

The Smarter Alternative

Variable displacement pumps like the Bosch Rexroth A15VSO Series 12 solve this problem elegantly: they only produce the flow your system actually needs at any given moment.

When your press is holding pressure but not moving? The pump swivels to minimal displacement, maintaining pressure with minimal flow. When you need full power for rapid advance? The pump instantly adjusts to maximum displacement. It happens automatically, hundreds of times per cycle.

The result:

  • 30-40% lower energy consumption in typical industrial applications
  • Reduced heat generation means smaller coolers and longer oil life
  • Quieter operation when running at reduced displacement
  • Extended component life due to lower thermal stress
The Energy Waste Problem Nobody Talks About

It’s Not Just About Saving Energy

Yes, the energy savings are compelling. But variable displacement brings other advantages that fixed pumps simply can’t match.

  • Precise Control: Need to vary press closing speed based on part thickness? Simple with proportional control. Want to sequence multiple actuators smoothly? Load-sensing makes it effortless.
  • System Flexibility: One variable pump can replace multiple fixed pumps with complex valve circuits, simplifying your hydraulic schematic and reducing potential leak points.
  • Modern Connectivity: With optional sensors, today’s variable pumps aren’t just hydraulic components—they’re smart devices that report operating status, predict maintenance needs, and integrate with your machine control.

The Question Isn’t “If” But “When”

The technology has matured. The energy savings are proven. The payback periods are measured in months.

The real question for manufacturers isn’t whether variable displacement makes sense—it’s why they’re still paying to run inefficient systems.

If you’re still operating fixed displacement pumps on variable load applications, you’re choosing to waste money every single shift. The A15VSO Series 12 provides a straightforward path to eliminate that waste while improving machine performance.

Curious about the potential savings in your facility? A Bosch Rexroth applications specialist can evaluate your current system and calculate your expected ROI. Most manufacturers are surprised by how quickly these pumps pay for themselves.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

When was the last time a “12-week lead time” helped your project stay on schedule.

The Hidden Cost of Custom Everything

There’s a trend in hydraulics toward custom solutions for every application. Custom manifolds. Custom valve assemblies. Custom pressure settings. It sounds sophisticated until you face real-world consequences:

  • Production schedules built around hoped-for delivery dates
  • Emergency repairs waiting on special-order components
  • Inventory nightmares from supporting dozens of unique part numbers
  • Engineering time spent specifying variations that add complexity without performance benefit

Sometimes the smartest solution is the one that’s actually available.

When Standard Means Better

Bosch Rexroth’s DBD 6-30 pressure relief valves prove that standardized doesn’t mean compromised. These direct-operated relief valves combine proven performance with the practical advantage of consistent stock availability.

Four sizes. 50 to 330 l/min flow capacity covers most mobile and industrial requirements.

Seven pressure ratings. From 25 to 630 bar—low-pressure mobile equipment through high-force industrial presses.

Multiple configurations. Cartridge, threaded, or subplate mounting. Tool-adjustable or hand-adjustable. Standard or enhanced corrosion protection.

The combinations you actually need? Ready to ship.

One Valve. Both Strengths.

Reliability Through Simplicity

DBD valves use direct-operated design where system pressure acts directly against a calibrated spring. When pressure exceeds the setting, the valve opens proportionally.

No pilot stages creating delays. No complex controls introducing failure points. Just mechanical reliability that works the same way every cycle.

This simplicity delivers real advantages:

  • Predictable response when pressure approaches limits—no pilot delays, just direct mechanical action.
  • Straightforward service when maintenance is needed—springs and seals, not multi-stage troubleshooting.
  • Consistent performance across temperature ranges and fluid conditions because mechanical operation doesn’t depend on pilot signal quality.

Built for Tough Conditions

Pressure relief valves often end up in exposed locations where environment challenges longevity. That’s why DBD valves offer corrosion protection levels matched to actual conditions:

  • Standard protection handles typical indoor industrial environments.
  • J3 protection (240-hour salt spray resistance) suits outdoor installations, mobile equipment, or humid conditions where condensation occurs regularly.
  • J5 protection (720-hour salt spray resistance) addresses marine applications, coastal facilities, or chemical processing where standard coatings fail within months.
  • The protection isn’t cosmetic—it’s functional reliability. Corrosion affects spring characteristics and sealing surfaces. Protected valves maintain calibration where unprotected alternatives degrade.

High Pressure Without Hesitation

Maximum ratings of 630 bar aren’t theoretical—they’re proven operating capability. Steel construction, hardened sealing surfaces, and precision manufacturing ensure DBD valves maintain performance and reliability when actually operating at high pressures.

For systems running 315 bar, 400 bar, or 630 bar, you’re not pushing design limits. You’re working within validated capability backed by decades of field installations.

The Availability Equation

Here’s what changes when critical components are consistently available:

  • Design confidence – Build schedules around actual delivery, not hoped-for dates.
  • Simplified inventory – Stock one reliable valve family instead of maintaining emergency supplies of multiple alternatives.
  • Faster emergency response – When pressure protection fails, replacement arrives in days.
  • Reduced planning stress – “Is it available?” stops being a question you ask weekly.

Quality That Shows Up Consistently

Rexroth manufacturing standards ensure every DBD valve meets specifications:

  • Precision machining of sealing surfaces
  • Controlled spring calibration with verification
  • Functional pressure testing before shipment
  • Consistent performance across every unit with the same part number

When you install a DBD valve, it performs like every other valve with that specification—predictable, repeatable, reliable.

When Simple Wins

Sophisticated solutions have their place. But when you need reliable pressure protection that’s available when projects demand it, proven when systems depend on it, and consistent when production requires it—standardized excellence beats custom complexity.

DBD 6-30 pressure relief valves: the smart choice that’s actually in stock.

Want to see how standardized reliability can simplify your next project? Contact Bosch Rexroth to discuss your pressure protection requirements.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

High-Flow Just Got Smarter: Inside the New CytroPac 2X Small Hydraulic Power

You spoke, we engineered. How direct customer feedback shaped the next evolution of compact, intelligent hydraulics.

When Bosch Rexroth introduced the original CytroPac, it fundamentally challenged what a hydraulic power unit had to look like. It eliminated sprawling, leaky 100-liter oil tanks, silenced shrieking pumps, and integrated the variable-frequency drive right on top of the power unit.

It quickly became the benchmark for machine tools and compact industrial automation. But at Bosch Rexroth, being an industry standard is just the baseline.

Over thousands of operational hours on shop floors worldwide, machine builders and maintenance managers gave us clear feedback on how to make CytroPac even better:

  • “We love the compact footprint, but we need more modularity to mount our own valves and handle large return flows.”
  • “Give us industrial-grade connectivity and continuous condition monitoring.”
  • “Help us cut energy consumption and CO₂ even further.”
  • “Make setup, maintenance, and visual diagnostics simpler for operators on the floor.”

The result is the CytroPac Series 2X—a power unit perfected by you.

Here is a closer look at what’s new in the 2X evolution and what it means for your machines.

Modularity That Fits Your Circuit, Not Ours

In the past, integrating directional or proportional control into a compact hydraulic circuit often meant mounting an external manifold block nearby, running extra hoses, and wasting valuable floor space.

The CytroPac 2X solves this with pre-engineered, factory-matched Functional Modules:

  • Standard Return Filter Module (M1): 10 µm filtration with integrated cold-start suppression monitoring to prevent false clogging alarms when oil is cold.
  • Leakage Oil Module (M2): Dedicated dual-return routing with built-in diffusers for pressure-free return of large volume flows, preventing oil foaming and aeration.
  • Valve Module (M3): An integrated NG6 (ISO 4401-03-02-05) interface plate mounted directly onto the power unit. You can now bolt standard Rexroth directional valves or multi-station manifolds straight onto the CytroPac.
  • Filter Module with DBV (M4): Integrated system pressure relief directly combined with the return filter.

Whether you need a standalone pressure supply or a complete, self-contained hydraulic control station, the 2X configures to your exact footprint.

Up to 80% Energy Savings: The Math Behind the Machine

Energy costs and carbon reduction mandates are no longer abstract targets—they directly impact operational margins.

The CytroPac 2X pairs high-efficiency motor options (including an IE5 PMSM servo motor on the 4.0 kW model and an IE4 asynchronous motor on the 2.2 kW model) with Bosch Rexroth’s Sytronix variable-speed pump drive.

Instead of running a fixed-speed motor that constantly dumps unused oil over a relief valve at high pressure, CytroPac 2X dynamically matches pump speed to the exact flow and pressure the cycle demands. In holding-pressure or idle phases, the motor slows down or drops into an intelligent sleep mode, slashing energy consumption by up to 80%.

The CytroPac 2X

Big Cooling Power in a Tiny 20-Liter Tank

How do you run 280 bar pressure and up to 38.5 l/min of flow out of a unit with only a 20-liter oil tank?

Traditional hydraulics rely on a massive 60 to 100-liter reservoir simply to let trapped air bubbles escape and allow oil to cool down before being drawn back into the pump. CytroPac eliminates this bulk using two patented innovations:

  • Degassing-Optimized Tank Flow: CFD-designed internal geometries guide returning fluid along precise paths that de-aerate oil almost instantly.
  • Heat Pipe Cooling Technology: Heat pipes transfer up to 2 kW of heat away from both the submerged motor/pump assembly and the oil reservoir straight into a heavy-duty aluminum cooling plate.

The result? 80% less hydraulic fluid to buy and dispose of, a 50% smaller machine footprint (1,200 cm² vs. 2,400 cm²), and an enclosure that completely muffles pump noise—operating at conversational sound levels even under full load.

Native Connectivity: Smarter Monitoring, Zero Hassle

Gone are the fragile RJ45 and Push-Pull connections of earlier units. The CytroPac 2X standardizes on rugged M12 Multi-Ethernet connectors, allowing seamless integration into fieldbus networks (Profinet, EtherCAT, Ethernet/IP, and Sercos).

The integrated frequency converter acts as an edge sensor node. In addition to standard digital switches, the 2X offers continuous 0–100% oil level sensing and 0–60°C continuous temperature logging. Connected to CytroConnect Solutions, your maintenance team can predict filter clogging, track thermal performance, and plan component servicing long before unexpected downtime occurs.

And for operators on the floor:

  • A bright Status LED bar integrated directly into the top hood provides immediate visual status from any viewing angle.
  • An optional 4.3″ HMI Touch Display right on the housing gives technicians instant readout of operating pressure, oil temperature, motor speed, and active alarms.
  • Our Commissioning Wizard gets the unit running in minutes via the USB service interface.

Designed for Global Deployment

For machine builders exporting to North America, regulatory certifications can be a costly bottleneck. The CytroPac 2X features optional cULus listing complete with an industrial-grade steel hood, alongside integrated Safe Torque Off (STO SIL 3 / PL e). You can specify one global design, confident that it meets electrical and mechanical safety standards anywhere in the world.

The Bottom Line

The CytroPac 2X proves that component evolution doesn’t happen in a vacuum—it happens when engineers listen to the people running the machines every day.

  • More modularity for custom control circuits.
  • More connectivity for Industry 4.0 monitoring.
  • More energy efficiency to cut your power bills and carbon footprint.
  • More simplicity for the technicians on your shop floor.

Ready to see how much energy and space you can save on your next machine build? Connect with your local Bosch Rexroth representative or explore the full datasheet at www.boschrexroth.com/cytropac.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

More Than a Pump: Why the A10VSO is Still the Heart of High-Power Machines

What do a 100-ton excavator, a forestry harvester, and a concrete pump truck have in common? They all rely on a hydraulic pump to do the heavy lifting, and for decades, one name has defined reliability in this space: the A10VSO.

But in a world of smart, connected everything, why does this classic workhorse still dominate? Because it solves the three problems that matter most to machine builders and operators: Power, Flexibility, and Uptime.

The Power Problem

High-power machines need to move heavy loads quickly and precisely. This requires a pump that can deliver high pressure and flow without fail. The A10VSO Series 32 is an optimized medium-pressure powerhouse, providing a nominal pressure of 280 bar for continuous use. This raw power, combined with fast control response times, gives operators the dynamic performance needed for demanding tasks.

The Flexibility Problem

Modern machines needs are unique to their application, which can require different pumps for each build resulting in multitudes of different configurations. This can be diifficult to track and manage. The A10VSO’s brilliant solution is its flexible universal through drive capability. Note only are all the through drives rated to 100% capability the flexibility offered by the universal through drive design allows a customer to streamline their inventory, keeping track of less part numbers and allowing for easy through drive conversions in the field. A single pump can be used as a base to create multiple different pump stacks; this brings flexibility back to the designers, headache free conversions in the field, and ease of mind to purchasers.

The Uptime Problem

Unplanned downtime is the enemy of profitability. A failed pump can bring an entire operation to a standstill. The A10VSO’s legendary reputation is built on its durability. Its robust swashplate design, high-quality bearings, and precision manufacturing mean it’s built for a long service life, even in the harshest conditions. It’s the kind of component you install and forget about—which is the highest praise a pump can receive.

Evolving with the Times

The A10VSO series 32 is a modern pump that respects and improves upon its heritage in many different areas; efficiency, noise and reliability. It’s available with a wide range of controls, from simple pressure compensators to sophisticated electro-proportional (EP) versions that integrate seamlessly with modern electronic control systems. This allows it to serve as the reliable foundation for both traditional and “smart” machine concepts.

The A10VSO is more than just a pump. It’s a problem-solver, an enabler of compact design, and a guarantee of uptime. It’s the trusted, powerful heartbeat inside the machines that build and shape our world.

More Than a Pump: Why the A10VSO is Still the Heart of High-Power Machines

Looking for a pump that delivers on its promises? Explore the A10VSO Series 32.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Why Machine Tool Builders Are Rethinking Hydraulic Power Units

Bosch Rexroth Web Editorial TeamEditor

When every square inch of factory floor space costs money, why are machine tools still using bulky hydraulic power units that waste half their footprint?

The Installation Space Problem

Machine tool manufacturers face a constant challenge: customers want more capability in less space. As workpieces get smaller and precision requirements increase, every component needs to justify the room it occupies.

Traditional hydraulic power units haven’t kept pace with this miniaturization trend. A standard 4 kW unit typically requires 100 liters of oil capacity, a separate control cabinet, external cooling circuits, and enough clearance for maintenance access. That’s a lot of real estate for what’s essentially a support system.

Four Innovations That Changed Everything

Bosch Rexroth’s CytroPac takes a completely different approach—one that eliminates the traditional “installation space eaters” through intelligent integration:

1. Optimized Tank Design
By rethinking how oil degasses, engineers reduced tank volume by 80%—from 100 liters down to just 20 liters. That’s the same hydraulic performance in half the space.

2. Integrated Frequency Converter
The fully-wired frequency converter with multi-Ethernet interface lives inside the power unit itself. No separate control cabinet required. For many installations, that eliminates cabinet space entirely.

3. Heatpipe Cooling Technology
Instead of bulky cooling circuits, passive heatpipes transfer thermal energy from the motor, converter, and oil to a central cooling water connection. This cuts another layer of complexity and space consumption.

4. Built-in Condition Monitoring
Integrated sensors monitor fill level, temperature, pressure, and filter contamination—feeding data directly to Industry 4.0 systems through standard interfaces like Ethernet-IP, EtherCAT, and Profinet.

The Quiet Revolution: Noise Reduction Benefits

Manufacturing environments face increasing pressure to reduce workplace noise levels—both for operator comfort and regulatory compliance. Traditional hydraulic power units contribute significantly to ambient noise through pump operation, cooling fans, and pressure fluctuations during load changes.

CytroPac addresses this through multiple integrated design features. The variable-speed drive eliminates the constant high-RPM operation that characterizes fixed-speed systems—the pump only runs as fast as needed for current demand. Combined with optimized tank design that reduces fluid turbulence and heatpipe cooling that eliminates noisy cooling fans, overall sound emissions drop noticeably. Machine tool builders report quieter operation that improves the working environment without requiring additional sound insulation or enclosures.

Energy Efficiency That Pays Back

Energy costs represent a growing portion of manufacturing overhead, making hydraulic system efficiency more than an environmental consideration—it’s an economic one. Traditional fixed-speed hydraulic systems run at full capacity regardless of actual demand, wasting energy during idle periods and low-load operations.

CytroPac’s integrated frequency converter fundamentally changes this equation. The variable-speed drive adjusts pump speed continuously to match hydraulic demand, consuming energy proportional to actual work performed. This approach complies with EU Eco-Design Directive 2009/125/EC while delivering measurable cost savings. In typical machine tool duty cycles with significant idle time between operations, energy consumption can drop 30-50% compared to conventional fixed-speed units. For manufacturers running multiple machines across shifts, those savings compound quickly—turning energy efficiency from a compliance requirement into a competitive advantage.

Why Machine Tool Builders Are Rethinking Hydraulic Power Units

What This Means in Practice

The total footprint reduction? Up to 50% compared to conventional designs of equivalent performance.

But space savings aren’t the only benefit. Machine builders also gain:

  • Faster installation: Connect power, cooling water, data interface, and hydraulic supply—done
  • Reduced assembly errors: Everything’s pre-wired and tested at the factory
  • Lower total cost: Smaller footprint means smaller machine frame or larger work envelope
  • Future-ready connectivity: Condition monitoring enables predictive maintenance strategies

The Control Cabinet Question

Here’s where integration really pays off. When the frequency converter, sensor technology, and motor are all pre-wired within the power unit, many machine designs can eliminate the hydraulic control cabinet completely.

Even when cabinet space remains necessary for other systems, reducing its footprint by 100% for the hydraulic portion creates flexibility for other components or simply reduces the overall machine size.

A Different Design Philosophy

CytroPac represents a fundamental rethinking of what a hydraulic power unit should be. Rather than optimizing individual components and assembling them, the approach integrates everything from the start—designing for the complete system performance in minimum space.

This matters because machine tool economics increasingly favor compact, flexible designs. When manufacturers can offer the same machining capability in a smaller footprint, they win business. When they can integrate hydraulics without sacrificing valuable working space, they differentiate their products.

Beyond Just Smaller

Miniaturization alone wouldn’t justify redesigning a proven technology. But when you combine space savings with energy efficiency (variable-speed drives only consume what’s needed), simplified installation (plug-and-play connectivity), and Industry 4.0 readiness (integrated condition monitoring), the value proposition becomes compelling.

Machine tool builders working in the 4 kW performance range now have an alternative to the “bigger tank, bigger cabinet, bigger footprint” tradition.

Want to see how much space CytroPac could save in your next machine design? Bosch Rexroth application engineers can evaluate your specific requirements and demonstrate the integration advantages.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Safety Solved: How STO Manifolds Deliver Critical Machine Protection Without the Engineering Headaches

Bosch Rexroth Web Editorial

When hydraulic system failures mean production stops, product gets damaged, or worse—people get hurt—you need more than components. You need solutions that work right out of the box.

Your Safety Challenge Just Got Simpler

Machine builders and plant operators face a persistent problem: meeting ISO 13849 functional safety requirements for hydraulic systems often means months of engineering, custom manifold design, complex safety assessments, and expensive validation. One miscalculation, and you’re back to square one.

The Bosch Rexroth STO (Safe Torque Off) Manifold eliminates this complexity entirely.

Problem Solved: Safety Functions That Work From Day One

The STOM series delivers pre-engineered, pre-validated safety shutdowns for hydraulic systems up to Category 4 PLe—the highest safety level defined by ISO 13849. Instead of designing your own safety circuits, you select from three standardized configurations based on four simple parameters:

  • Pressure (up to 315 bar)
  • Flow rate (up to 1750 l/min)
  • Required safety level (Cat 3 or Cat 4)
  • Functions needed (STO, SDE, SLS)

Your hydraulic problems—solved. From design constraints to uptime issues, we identify root causes and deliver effective hydraulic solutions.

Three Safety Functions in One Compact Block

Safe Torque Off (STO): Two-channel, position-monitored blocking from P1 to P2 ensures leak-free shutdown of entire machine areas or systems. When it must work—you call us.

Safe Decompression (SDE): Controlled pressure relief through dual bypass valves with flow-limiting nozzles safely drains downstream pressure in under 300ms in most applications. No sudden movements. No unexpected energy release.

Safe Limited Speed (SLS): Pre-compression through the same bypass circuit minimizes switching shocks, extends component life, and reduces noise—while meeting functional safety requirements for controlled flow.

The Engineering Time You’ll Save

Traditional custom safety manifolds require:

  • 40-80 hours of safety circuit design
  • Risk assessment documentation
  • Component selection and validation
  • Safety logic programming
  • Final system validation

With STOM, you select a material number from a datasheet. Documentation, validation calculations, and installation instructions are included. Every solution is engineered to simplify your machine lifecycle: Design → Installation → Operation → Maintenance.

Real-World Reliability From Decades of Expertise

The STOM portfolio builds on proven Bosch Rexroth valve technology—pilot-operated check valves (SL) in sizes 20/30, and actively controllable 2-way cartridge valves (LC2A) in sizes 32/40. These aren’t experimental components. They’re field-tested workhorses now configured for functional safety.

Galvanized surface coating provides long-term corrosion protection. Compatibility with mineral oils (HLP) and flame-resistant fluids (HFC, HFDU) means retrofit flexibility. Identical electrical control across all nominal sizes simplifies commissioning and spare parts management.

Stop Paying an Electrician to Wire Your Hydraulic Valves

Bosch Rexroth STO (Safe Torque Off) Manifold 

When Performance Bottlenecks Impact Output

Heavy-duty presses, metallurgical plants, and test benches face a common challenge: hydraulic area shutdowns that meet safety standards while minimizing production disruption.

A metal forming facility recently integrated STOM-32B4E manifolds for zone isolation. Results:

  • 87% reduction in safety engineering time versus custom design
  • Closing times under 280ms with 200-bar system pressure
  • Safe decompression in 1.2 seconds for 12-liter downstream volume
  • Zero safety-related downtime in first 18 months of operation

When performance bottlenecks impact your output, our specialists solve them with data-driven, high-performance hydraulics.

Your Challenges Just Became Manageable

Whether you face unpredictable downtimes during retrofits, need breakthrough safety compliance for new machine designs, or require reliable area shutdown for high-risk operations—STOM manifolds make your challenges manageable.

We’re not just a hydraulics supplier. We are the problem solvers behind your productivity—reducing downtime, simplifying design, streamlining installation, and optimizing performance.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

5 HYDRAULICS MYTHS
Guest Contributor: Dr. Steffen Haack, Bosch Rexroth

br_hydrolicmyths_hero_dec19.jpgNo drive technology is more efficient, compact and robust than hydraulics when dealing with forces in excess of 600 kN. So why is it that the importance of hydraulics is often overlooked in the training and development of our young engineers?

In the modern manufacturing setting, movement is everything along with the resulting data. Little thought is given to hydraulic technology, that is until drive physics comes into play. This is when hydraulic technology comes into its own in managing large forces and delivering robust performance.

Here’s a connected hydraulics ‘Myth Buster’ that demonstrates how the latest smart hydraulics are more versatile and cost-effective than you ever imagined.

THE MYTH: Installation is complex

BUSTED: Designers are no longer required to develop an in-depth knowledge of fluid mechanics and technology and increasingly look for plug & produce modules. These ready-to-install modules simply need an electrical current and a connection to the control communication.

THE MYTH: Commissioning takes time

BUSTED: Our smart, connected hydraulics are now commissioned with the same engineering tools as electric drives and control systems. Functions previously carried out hydromechanically are handled by the latest drive software. There are even software assistants available to guide technicians through the commissioning process and suggest suitable parameters.

THE MYTH: Hydraulics waste energy

BUSTED: There’s a preconception that hydraulics are more energy-intensive than other technologies, but things have changed dramatically. Variable-speed pump drives generate the flow in line with demand and reduce speeds accordingly under partial load conditions. Compared to constantly driven pumps, they reduce power consumption by up to 80 percent – a level consistent with that of electric drives of the same size.

THE MYTH: Hydraulics aren’t IoT ready

BUSTED: Smart hydraulics are a well-established part of IoT in production. Analog valves can be made digitally visible cost-effectively thanks to IO-Link and exchange data available through the control system. Smart valves, with their own control electronics and state of the art field bus connection, are as convenient to use as electric drives.

THE MYTH: Hydraulics are high maintenance

BUSTED: Hydraulics offer a distinct advantage when monitoring operating states and deducing possible wear and expected life cycle. With a few pieces of sensor data, such as pressure differential, oil temperature, optically measured contamination or pressure increase over time, software can assess the health of the system.

This myth busting technology is included in our latest generation of hydraulic power units, allowing young designers and businesses to benefit from all the advantages of our modern, connected innovations.

 

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Hydraulics Meets Internet of Things: Avoiding Machine Downtime the Intelligent Way

Guest Contributor: Luisa Franz, Bosch Rexroth

 

 

IoT-capable hydraulic power unit ensures efficient production

With the newly developed, intelligent CytroBox unit, Rexroth combines the benefits of hydraulics with low energy consumption and software-based functions. The integrated CytroConnect IoT service ensures higher availability and avoids unplanned downtimes. With this IoT service, operators can monitor operating statuses and plan maintenance in a cost-effective manner. As a result, fluid technology has taken a further step towards the factory of the future.

The digitalization of mechanical and plant engineering means more than decentralized intelligence, integrated sensors and connectivity. This applies to hydraulics too. With its power density and immunity to impacts and vibrations, hydraulics plays a central role as an important drive technology in Industry 4.0 too. The compact CytroBox unit is revolutionizing hydraulic pressure supply. CytroBox is a modular hydraulic power unit for the medium performance range from 7.5 kW to 30 kW. It comprises optimally tailored, impressively compact components. Compared to previous units, considerable amounts of space can be saved.

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75% less oil

One of CytroBox’s unique selling points is it compactness. This is possible because the hydraulic power unit can be integrated into a factory like a control cabinet, i.e. upright. The tank no longer supports all other components – Rexroth developed a special supporting structure for this purpose. In addition, a degassing flow-optimized tank is used. On the basis of extensive CFD simulations, the developers improved the tank geometry so skillfully that the new unit needs only a quarter of the oil required by classic designs: instead of 600 liters, 150 liters are now enough – with at least the same service life. The drive unit – a component which usually takes up a large amount of space in hydraulic power units – is equally compact. The asynchronous servo motor has been replaced by a synchronous servo motor. This is the most efficient motor design, producing the same torque even though it is 80 to 90% smaller. The manifold too was redesigned: thanks to 3D printed sand cores, the block including the internal flow geometry is now cast. As a result of this flow-optimized inner structure, less material and space are required. Thanks to all these measures, the CytroBox has a footprint of just 0.5 square meters instead of one and a half to two square meters. This represents a saving of up to 75%. On top of this, there are energy savings of up to 80% as well as a 10 dB(A) reduction in noise emissions. As a result, noise emissions are lower than 75 dB(A).

Connected for the factory of the future

In the CytroBox, machine manufacturers will find a ready-configured drive controller with numerous integrated functions. Various sensors provide information on the current filter, oil or drive status. The collected sensor data are bundled via IO-LinkMaster and pre-processed by the drive controller so that they can be integrated flexibly into modern machine designs. This means that the CytroBox is IoT-ready.

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CytroConnect Monitor

With the CytroConnect digital service, operators have all information regarding the CytroBox at their fingertips at all times – whether it be information regarding the standardized visualization of the component and operating status or chargeable IoT services such as forthcoming maintenance work and predictive maintenance analyses using Rexroth’s Online Diagnostics Network (ODiN).

The data collected are transferred to the browser-based CytroConnect Monitor web dashboard via Multi-Ethernet or 4G-LTE. As a result, operators can be kept up to date regarding the current operating status and key status indicators on any end device (tablet, smartphone, PC). This plug and play service is free of charge and can be used without additional installation work. CytroConnect is implemented in the CytroBox as standard.

Greater availability thanks to additional analysis functions

In addition to the CytroBox’s automatic status monitoring, maintenance personnel and maintenance managers can add extra solutions for various applications as add-ons. These pay-per-use payment models include additional IoT analysis tools and can be subscribed to on a monthly basis.

For optimizing maintenance processes, the CytroConnect Maintain module offers access to historical sensor data as well as messages if maintenance is required or in the event of critical operating statuses. Pre-defined and custom rules allow customers to improve their maintenance strategy on an ongoing basis. Customers benefit from scalable software solutions from the Bosch IoT portfolio such as the Nexeed Production Performance Manager and the integrated know-how of the Rexroth domain specialists. The Nexeed Production Performance Manager is a condition monitoring software solution for systematic production optimization.

CytroConnect_Addons.jpg

CytroConnect Maintain

With CytroConnect Maintain, data concerning the most important components for reliability and operating life (the hydraulic oil and the drive unit) are assessed. Comprehensive insights into the correlation between the speed of the servo motor and the flow allow the monitoring of system leakage, while correlations between motor data and the operating pressure allow conclusions regarding drive behavior. The leakage sensor, temperature and level sensor, particle sensor, water sensor and oxygen sensor are additional data sources which can be used to make a status diagnosis.

Planning predictive maintenance efficiently

A further add-on, CytroConnect Predict, uses the machine learning algorithms of the Rexroth Online Diagnostics Network (ODiN) for a predictive analysis of the system. With this IoT service, the power curves for a wide range of components are recorded for data analysis purposes. In the event of deviations, the system automatically calculates the expected remaining operating life of the relevant component and informs the operator immediately via a push message. As a result, predictive maintenance application cases can be taken into account predictively in the operator’s maintenance plans, thus ensuring maximum availability.

Conclusion

This new form of hydraulics is energy-efficient, quiet, space-saving and intelligent. With the integrated CytroConnect IoT service, the CytroBox offers anything from transparent, efficient machine monitoring to intelligent predictive maintenance measures. Thanks to the CytroBox, fluid technology is now one step closer to the factory of the future.

www.cytroconnect.com

www.boschrexroth.com/cytro

 

cropped-cmafh-logo-with-tagline-caps.pngCMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.