Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RE 30 241/02.02
Replaces: 30 240

External control electronics for the DFE1-

control of A10VSO axial piston pumps

Analogue amplifier, configurable

Type VT 5041

H/A/D 6639
Series 2X
Type VT 5041-2X/.

Table of contents Features

Contents Page – Integral part of the SY.DFE1 pressure and flow control system
(series 1X and 2X) for controlling A10VSO... axial piston units
Features 1
with DFE1 control
Ordering code 2
– Implementation of the electronic functions of the DFE1 control;
Functional description 2 closed-loop pressure and swivel angle control; optional power
Block circuit diagram / pin assignment 3 limitation
Technical data 4 – Pressure controller can be matched to existing hydraulic fluid
Indicator/ adjustment elements 5 volume (actuators plus lines)
Unit dimensions 6 – Differential amplifier inputs
Supplementary information 6 – Controller for valve spool position
– Minimum value generator for pressure and swivel angle
controller
– Self-clocking output stage
– Pressure-related leakage compensation (can be switched off)
Card holder: – Polarity reversal protection for voltage supply
– Type VT 3002-2X/32, see RE 29 928
Single card holder without power supply unit – Switchable actual pressure input (current, voltage, range)
Power supply unit: – LED lamps on front panel:
– Type VT-NE32-1X, see RE 29 929 • Error / no enable “H1“
Compact power supply unit 115/230 VAC → 24 VDC • Internal supply voltage “H2“
• Output 1 (60 VA) for supplying amplifier card type VT 5041 – Indicator instrument for actual swivel angle value on front
• Output 2 (25 VA) for supplying pressure transducers; panel (optional)
e.g. type HM 12 or HM 13, see RE 29 933 – Power limiter with internal or external command value
selection (optional)

VT 5041 1/6 RE 30 241/02.02

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Hydraulics

Ordering code

VT 5041 – 2X/ /*

External control electronics for the DFE1 control of Further details

A10VSO axial piston pumps in clear text

Series 20 to 29
(20 to 29: unchanged technical data and
pin assignment) = 2X

Additional functions:
– Without power limiter, without indicator instrument =1
– With power limiter, with indicator instrument =3

Preferred types
Material no. Type
00749982 VT5041-2X/1
00749983 VT5041-2X/3

Functional description

VT 5041-2X analogue amplifiers are designed as plug-in cards in
Euro-format. As a standard, they are provided with one command
value input each for pressure and swivel angle [1] (power limitation
optional). The actual pressure value is sensed by a pressure trans-
ducer. A position transducer on the pump acquires the actual swivel
angle value. The acquired actual values are processed in an amplifier
[10 and 12] and compared with the specified command values. Mini-
mum value generator [4] ensures that only the controller assigned to
the relevant working point is automatically activated. The output sig-
nal of minimum value generator [4] becomes the command value for
the closed control loop of the valve.
The optional power limiter is automatically activated when a suit-
able command value is fed forward. The power command value can
be provided internally or externally. When required, it acts via a mini-
mum value generator [14] directly on the swivel angle controller [3].
The actual valve position (position of the valve spool) is sensed by an
inductive position transducer. Oscillator/demodulator circuit [10] pro-
cesses the signal. Valve spool position controller [5] establishes and
processes the system deviation. The output signal of valve controller
[5] forms the command value for self-clocking current output stage
[6], which controls the proportional solenoid of the valve.
The amplifier card is fitted with an error signal output, to which a
voltage of 0 V is applied in the case of an error. At the same time, LED
"H1" lights up and the output stage is de-energised.
The following events result in an error message:
– The actual pressure value is greater than the permissible system
pressure (pact > 10 V)
– Enable signal missing at connection 26c
– Excessive output stage temperature
– Cable break or swivel angle feedback out of range
– Cable break or spool position feedback out of range
– Cable break “proportional solenoid“
– Cable break “pressure transducer“ (only with setting 4 to 20 mA)
In the case of an error, the output stage is de-energised and the
valve spool pushed by a spring to its mechanical end position. The
error can only be acknowledged by a reset of the enable signal.
With the help of an offset potentiometer [15] it is possible to com-
pensate for pressure-related pump leakage via the closed swivel angle
control loop.
[ ] = Reference to the block circuit diagram on page 3

RE 30 241/02.020 2/6 VT 5041

VT 5041

Block circuit diagram / pin assignment

With VT 5041-2X/3... only +
18a Power limiter
R3 active (^= 24 V)
18c +
pcomm = (p • α): 0 to + 10 V u +
14 Swivel angle control
20c + 16a
Reference potential u – active =
(^ 24 V)
1
5 + +UB
6c + 1 J1...J5 6
28c
αcomm = 0 to + 10 V u
u Proportional
Reference potential 4c u PD 4 PD i 30c solenoid

1 2 5
+UB
R1 R2
J10 ϑ 2a
12 +2 9 Error message (^
= High)
0 to 5/10 V or 8c 2c
pact = Error message (^
= Low)
0/4 to 20 mA i(u)
J6...J8 u ≥1
Reference potential H1
10c 15
11 R4 24c pact: 0 to + 10 V Measuring
– 3 J9 12c αact: – 10 V to + 10 V outputs
– 10 to + 10 V 14c
αcomm = u
13 P
3/6

Reference potential 16c u =

– 9 2
1 + 4 3 6 ≈
8a 1
10
= 4a 4
≈ 6a 3
26c Valve displacement
Enable (> 21 V) R6 R7
26a
+UB transducer
32a 8 7 Shield 1)
30a + 15 V = 14a (2)
+ UB ≈
+ = – 15 V 10 Swivel angle
= 10a 1
transducer
28a H2 7 8 ≈ on pump
0 V (⊥)
20a R8 R9 12a 2( )
– 15 V
22a 26a
⊥ Shield 1)
24a For explanations for indicator and Note:
+ 15 V
RE 30 241/02.02

adjustment elements (H, R), – The connection of the swivel angle transducer is valid for a clockwise
1 Differential amplifier 6 Output stage 11 Input amplifier see page 5 rotating pump
2 Pressure controller 7 Output stage enable 12 Divider
8 Power supply unit 13 Minimum value generator
1) For notes on shielding, see ("( )" anti-clockwise rotating pump)
3 Swivel angle controller

Hydraulics
Industrial
4 Minimum value generator 9 Cable break detector 14 Indicator instrument engineering notes for the – Differences between αcomm (socket 3) and αact (socket 4) result from the
5 Valve spool position controller 10 Oscillator/demodulator 15 Leakage compensation complete system, RE 30024-01-B setting of R4 (leakage compensation)
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Hydraulics

Technical data (for applications outside these parameters, please consult us!)

Operating voltage UB 24 VDC + 40 % – 10 %

Operating range:
– Upper limit value uB(t)max 35 V
– Lower limit value uB(t)min 21 V
Power consumption PP 35 VA
Current consumption Inom 0.6 A (Imax = 1,25 A)
Fuse IF 1.6 A T
Inputs:
– Command values (pressure, swivel angle) Ui 0 to 10 V; Re= 100 kΩ
– Actual value (pressure) Ui 0 to 5 V or 0 to 10 V; Re= 100 kΩ
Ii 0 to 20 mA or 4 to 20 mA; Re= 500 Ω
– Power selection (p • α)comm (with VT 5041-2X/3... only) Ui 0 to 10 V; Re= 100 kΩ
– Enable Ue > 21 V (use relay with contact for currents < 10 mA)
Outputs:
– Output stage
• Solenoid current/resistance Imax 2.5 A; R(20) = 2 Ω
– Driver for inductive transducers:
• Oscillator frequency f ca. 5 kHz
• Voltage amplitude (USS) Ua 10 V
– Signal voltages
• Actual value (pressure, swivel angle) U 0 to 10 V
• Swivel angle control active U Uo –1 V
• Power limiter active (with VT 5041-2X/3... only) U Uo –1 V
– Auxiliary voltages U ± 15 V ± 3 %; 10 mA
– Error message
• L-active Uo ≥ UB – 5 V; 10 mA (short-circuit-proof); error at Uo < 1 V
• H-active Uo < 1 V; error at ≥ UB – 5 V; 10 mA
– Measuring sockets
• Pressure command value (pcomm) “1“ U + 10 V =^ 100 %
• Actual pressure value (pact) “2“ U + 10 V =^ 100 %
• Swivel angle command value (αcomm) „3“ U – 10 V =^ 100 %
• Actual swivel angle value (αact) “4“ U + 10 V =^ 100 %
• Spool position command value (scomm) “5“ U ± 10 V =^ ± 100 %
• Actual spool position value (sact) “6“ U ± 10 V ^= ± 100 %
Type of encoder:
– for pump IW 9 (throttle circuit; ± 4 mm; 3-wire connection )
– for valve DM2 (transformer circuit; ± 0.6 mm; 4-wire connection )
Type of connection 32-pin male multi-point connector, DIN 41 612, form D
Card dimensions Euro-card 100 x 160 mm, DIN 41 494
Front panel dimensions:
– Height 3 HE (128.4 mm)
– Width conductor side 1 TE
– Width component side
• VT 5041-2X/1... 5 TE
• VT 5041-2X/3... 9 TE
Permissible operating temperature range ϑ 0 to 50 °C
Storage temperature range ϑ – 20 to + 70 °C
Weight
• VT 5041-2X/1... m 0.19 kg
• VT 5041-2X/3... m 0.21 kg

Note:
For details on Environment simulation tests in the fields of
EMC (electromagnetic compatibility), climate and mechanical stress,
see RE 30 024-U (declaration on environmental compatibility).

RE 30 241/02.020 4/6 VT 5041

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Indicator / adjustment elements: VT 5041-2X/1 and VT 5041-2X/3 from series 25

Leakage Jumper Actual press. Jumper

compensation J9 value gain J10
ON on Without off
OFF off Double on

R8
J9 R6
R7 R9
R4
J10
H1 J11 J1 J2 R31)
H2
off
R2
on

J6
J3 J4 J5 R1
on F1
J7 J8 1,6 A T
off

D-component of the pressure controller

Hydraulic fluid volume (in litres) Jumper position
Actual change-over pressure value in the system (actuators and lines) J3 J4 J5
Input signal Jumper position ≤ 5.0 off off off
J6 J7 J8 7.5 off on off
0 to 10 V off off off 10.0 on on off
0 to 5 V off off on 15.0 on off on
0 to 20 mA on off off 20.0 off on on
4 to 20 mA on on off 25.0 on on on

... Factory-setting of jumpers P-component of the pressure controller

P-gain Jumper position
J1 J2 J11
Potentiometers: 2 on on on
R1 Actual pressure value zero point 2.4 on off on
R2 Actual pressure value adjustment 2.7 on on off
(Factory setting: right-hand limit stop = max. gain) 3 off on on
R31) Power command value 3.4 on off off
–> is added to an externally provided command value 4 off off on
(Factory setting: left-hand limit stop = max. power) 4.8 off on off
R4 Leakage compensation 8 off off off
(factory setting: left-hand limit stop = min. compensation)
R6 Valve displacement transducer zero point
R7 Amplitude of valve displacement transducer (factory setting)
R8 Swivel angle position transducer zero point
R9 Swivel angle position transducer amplitude (factory setting)

LED lamps:
H1 Error / no enable (red) For further information and notes, see commissioning instructions
H2 Internal supply voltage (green) for SYDFE1-2X closed-loop control systems (RE 30 024-02-B)!
1) with VT 5041-2X/3 only

VT 5041 5/6 RE 30 241/02.02

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Unit dimensions (Dimensions in mm)

VT 5041-2X/1 VT 5041-2X/3

R4 R4
H1 H1
H2 H2 +

50 100
R2 R2
3HE (128,4)

100
89
100 50
–
1 2 1 2
3 4 3 4
5 6 5 6
7 8 7 8
VT VT

15
5041 5041

6TE (30,1) 10TE (50,5) 2

7 165
186

Potentiometers: Measuring sockets:

“R2“ → Matching of amplitude pact (pressure transducer) “1“ → Pressure command value pcomm
“R4“ → Leakage compensation “2“ → Actual pressure value pact
LED lamps: “3“ → Swivel angle command value αcomm
“H1“ → Error / no enable “4“ → Actual swivel angle value αact
“H2“ → Internal supply voltage “5“ → Spool position command value scomm
“6“ → Actual spool position value sact
“7“ and “8“ → Reference potential / mass

Supplementary information

Note: Electrical signals processed by control electronics (e.g. actual value“) must not be
used for switching safety-relevant machine functions!
(See European standard “Safety requirements for fluid power systems and components
– hydraulics“, EN 982)

For detailed instructions and notes on engineering and commissioning, see:

– Engineering instructions for SYDFE1-2X closed-loop control systems (RE 30 024-S)
– Commissioning instructions for SYDFE1-2X closed-loop control systems (RE 30 024-B)

Bosch Rexroth AG Bosch Rexroth Limited

Industrial Hydraulics
D-97813 Lohr am Main Cromwell Road, St Neots,
Zum Eisengießer 1 • D-97816 Lohr am Main Cambridgeshire PE19 2ES The specified data is for product description
Telefon 0 93 52 / 18-0 Tel: 0 14 80/22 32 56 purposes only and may not be deemed to be
Telefax 0 93 52 / 18-23 58 • Telex 6 89 418-0 Fax: 0 14 80/21 90 52 guaranteed unless expressly confirmed in the
eMail documentation@rexroth.de E-mail: info@rexroth.co.uk contract.
Internet www.boschrexroth.de Internet www.boschrexroth.co.uk Copyrights – Subject to revision

RE 30 241/02.02 6/6 VT 5041