Mannesmann Rexroth (Compendio 2) - Tecnica de Valvulas Proporcionales y de Servovalvulas

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Project manual RE 00847/10.08

Replaces: 07.07
Proportional valve technology
Trainer's manual
Foreword 1 Bosch Rexroth AG I RE 00847/07.07
Foreword
The present trainer's manual is intended for trainers and instructors in the field of
proportional valve technology. It describes projects that are oriented specifically
towards practical application examples of electrohydraulic control technology.
It is assumed that the trainee has a basic knowledge of hydraulics and electrics.
Generally, it must be noted that the project results documented in this manual
are intended as a guideline for the trainer and instructor. We recommend that
the projects be worked off starting from 01.
Before the projects are dealt with, the experiments relating to basic principles
of hydraulics should have been carried out.
The existing set of components was extended for the projects covering propor-
tional valve technology.
Explanations with regard to the training stand can be found in the relevant op-
erating instructions.
Project / train- Specific project/trainer information is provided at the end of each project exer-
er information cise. This information is included exclusively in the trainer's manual.
Foreword 2 Bosch Rexroth AG I RE 00847/07.07
Notes
Introduction 1 Bosch Rexroth AG I RE 00847/07.07
Introduction
History of pro- The first hydraulic systems were operated using water; the origins date back to
portional valves the medieval times. The use of oil has turned out to be more advantageous due
to the lubrication of pumps and the reduced risk of corrosion and erosion.
In the beginnings of hydraulics for industrial applications, only on/off and servo-
valves were available. As long as the traversing speed of the moved masses
was relatively slow, it was sufficient to use on/off valves.
For dynamic applications that also demand precision, e.g. in steel rolling mills,
servo-valves were employed. Servo-valves have their origin in aviation hydraulics
in the 1930s.
The use of on/off valves reaches its limits, if large masses are to be moved at
higher speeds. An on/off valve of size 6 can close within 50 ms. However, this
means that the machine part is decelerated within this time.
Also a changeover to another speed is accordingly abrupt. Here, large accel-
eration and deceleration forces are generated, which result in corresponding
stress on the machines.
Deceleration valves are used for the position-dependent, stepless accel-

eration or deceleration of hydraulically moved masses.
Deceleration valve and cylinder with switching mechanism
Initial position open, with check valve, main flow throttle and off-line throttle
Mechanically operated proportional valves were developed, which were actu-

ated by means of roller plungers and mechanical profiled bars. This technology
was perfected in mechanical-hydraulic copiers in machine tools, which exactly
follow a mechanical profile. Unfortunately, these controls were very difficult to
adjust, for a new profile had to be implemented in each case.
Section, deceleration valve with lever actuation, main flow throttle (5), off-line throttle (7) and by-
pass check valve (6), type FRH
Notes
The emerging open and closed-loop control technology with its high flexibility
necessitated electronically controllable hydraulic valves.
Servo-valves meet this requirement, but were much to complex and expensive
for most of the applications.
Hydraulic valves had therefore to be developed, which can be steplessly adjusted
by means of an electronic system, while being simple, rugged and cost-efficient.
This was the "birth" of proportional valve technology.
Proportional directional valves were developed on the basis of on/off directional
valves, that is, a spool in a cast iron housing.
Decisive features of proportional valves are spools with control lands, specific
solenoids and special electronics for optimum operation of the valves. With the
help of the electronics it was now possible to steplessly adjust the valve aper-
ture (command value) and the spool velocity (ramp), which allowed the machine
speed and in particular acceleration to be exactly controlled.
Now, it was possible to adjust the machine movement continuously and pro-
portionally to an electrical signals. This resulted in the designation "proportional
valve“. This technology provided higher speeds and hence higher productivity.
Another aspect was that the motion sequences could be programmed with an
electronic control.
The trend in the further development of proportional valves and electronics was
towards reliability, higher dynamics, increased accuracy and further cost reduc-
tion. With today's proportional valves, the valve electronics can be mounted
directly onto the valve.
Modern proportional directional valve with integrated On-Board Electronics (OBE)

Application, advantages
Due to their ability to handle large forces and their compact design, hydraulic
controls provide the greatest benefit, wherever large masses are to be moved
at high dynamics. The use of proportional valve is often generally necessary in
these applications.
Modern machines are electronically open- or closed-loop controlled; the transfor-
mation of electrical signals into hydraulic movements and forces is accomplished
with proportional valves. They can be used to efficiently control velocities and
acceleration, and the machine can follow the motion profiles given by the con-
trol. This is difficult and complicated to realize with on/off valves and leads to
jerky and abrupt operation of the machine. In many applications, a machine part
is to move forward quickly, then decelerate and approach a certain position or
the end position at low velocity, e.g. in plastics processing machines, presses,
machine tools, lifting platforms, etc.
Heavy machine parts are not be decelerated abruptly, because the forces gen-
erated by this process would exert great stress on structural parts. It can easily
be imagined what happens, when two machine parts clash at high velocity. The
idle stroke is to be performed as quickly as possible, and the actual working
stroke at a velocity that is optimal for the individual process.
All of these requirements can be met with proportional valves.
Modern hydraulic press

Imparting knowledge through project work

The present Project Manual Proportional Valve Technology can be used to
impart the required specialist knowledge of hydraulic control technology in
practice-oriented applications. The logically structured project work is to make
the trainee familiar with:
Training • the physical laws of, for example, pressure differential, opening cross-section
contents and flow
• specific symbols
• signal flows
• the relationship between command value and velocity
• function and meaning of ramps
• commissioning and optimization of an electrohydraulic system
• adjusting a control according to specified values
The project tasks and project work described in the Project Manual Proportional
Valve Technology provide trainers and trainees with information and instruments
that will help them comply with the demands made on the transfer of specialist
know-how in the field of hydraulics.
Specialist com- The objectives described are geared to the development of competence to act.
petence The trainee will develop his or her competence to act from the capability and
willingness to solve tasks and problems and evaluate results in a target-oriented
manner, skillfully, methodically and independently on the basis of technical
knowledge and skills.
Professional
competence to
act As mentioned before, the trainee is to work off the project task or the project
order in 6 steps.
1. Informing
Based on the project definition, the trainee is to get a clear idea of the finished
solution, including any required details. This is achieved through a systematic
analysis of the project documentation and, if required, by asking questions.
Possible questions: • What is to be done?
• Have I understood the task completely?
• Which hydraulic component/system is to be dealt
with?
2. Planning
Planning means the theoretical preparation and anticipation of the concrete
execution. In detail, planning requires competence to handle the project order
and to organize the project handling steps.
Possible questions: • How to proceed?
• What knowledge is required?
• Which aids are available?
• Are there comparable applications in my company?
3. Decision-making
After the planning stage, the trainee determines the aids to be used, e.g. which
data sheets are required for coping with the project task. He/she decides on the
sequence and the interrelationships of the individual project steps. Moreover, a
decision should be made as to whether it would be easier to solve the project
task in a team.
Possible questions: • Which hydraulic components will be used?
• How can you know that technical data sheets are up
to date?
• Have I utilized all available sources of information?
• Are the prescribed safety instructions at hand?
4. Executing:
The order is to be executed according to the work instructions given in the
chapter "order execution", taking all safety notes into account. After a thorough
preparatory phase, the trainee is to carry out the project order largely on his/her
own. After the solution was worked out in writing, it should be verified or ques-
tioned, whether the right attempt at a solution was selected.
Depending on the project order, the possibilities of execution may be limited.
This is valid, for example, in the case of costly work in the field of information
technology.
Possible questions: • Have I chosen the correct sequence?
5. Checking
The trainee must check intermediate results as early as during the execution
stage and finally the result of the customer requirement. In some cases, the result
can be compared with the manufacturer's documents. In the case of measuring
exercises, it must be checked, whether the measured results are realistic.
The documentation should also be finally corrected, improved and completed.

This also includes the preparation of a final report. After completion, the trainer
makes a final check.
Possible questions: • Was the control properly installed?
• Has the project objective been complied with?
• Is the customer satisfied with the project result?
• Which documentation is required?
• Is the result completely documented in the correct
order?
6. Evaluating
In the final evaluation phase, an external or self-evaluation is to be carried out
on the basis of a comparison of project order documents, the installed control
and results of measurements and checks.
Faults, if any, and their causes must be analyzed and possibilities discussed as
to how faults can be avoided in the future.
The trainee must learn to assess his/her strengths and weaknesses and develop
objective quality standards for his/her acting, which ultimately leads to personal
competence. The evaluation can be finalized in a technical discussion, possibly
also in a discussion with the customer.
General notes:
For didactic reasons, we refer exclusively to trainees and trainers in the present
manual. We expressly point out that these terms include all persons involved
in the basic and advanced training: Instructors, teachers, project managers,
etc., whether male or female.
Procedural In this manual, we do not give notes on procedural knowledge (explanatory

knowlege knowledge). It is the knowledge of how to achieve a certain result with which
measures, procedures or processes. In this case, how the learning target can
be reached.
The present manual must be understood as a tool for providing the required
core and specialist qualification that must be imparted in an integrated form
through independent planning, executing and checking according to regula-
tions for vocational training in industrial metalworking professions.
Pictograms The pictograms, which are used as recurrent symbols, are to transfer important
information as quickly as possible in the form of a simplified graphical repre-
sentation and independently of languages.
Safety aspects
Safety and the economic use of resources are essential demands that are placed
on modern plant and machinery and serve to protect people. These two require-
ments have in common that they have to be taken into account as early as pos-
sible, that is, at the product concept stage. Only in this way can optimized and
low-priced solutions be found. Safe machines with low consumption demonstrate
that the manufacturer masters his processes; they are a quality feature.
In order that hazards to plant and machinery can be recognized, safety regula-
tions, product information and operating instructions must be observed.
Only if these operating instructions, safety notes and product information are
observed can the trouble-free operation of Rexroth products be ensured.
The present Project Manual Proportional Valve Technology includes warning

notes, which precede instructions for activities that involve a risk of personal
injury or damage to property. The prescribed precautions for averting risks must
be taken.
Conventions
This symbol refers to imminent danger that, if not avoided, can
lead to severest injuries or death.
Warning
This symbol refers to a potential risk, which can lead to light or

serious injuries or damage to property.
Caution
This symbol refers to supplementary information.
Note:
The electrohydraulic components and systems described in this Project Manual
are technical equipment, which is not intended for private use.
The use for the intended purpose also includes that the safety regulations,
product information and operating instructions described in the following are
read and understood.
Qualification of Installation, commissioning and operation, disassembly, upkeep and maintenance

personnel require fundamental knowledge of mechanics and electrohydraulics as well as
the knowledge of related technical terms. In order to ensure operational safety,
these activities may only be carried out by a corresponding specialist or by an
instructed person under the supervision of a specialist.
A specialist is, who, due to his/her professional training, his/her knowledge and
experience and the knowledge of relevant regulations, can asses the duties
assigned to him/her, recognize potential risks and take suitable precautions. A
specialist must observe relevant technical rules.
Consequently, this means that the trainer must point out potential risks to the
trainee and provide information of how to avert such risks.
Work carried out improperly on electrohydraulic components

and systems involves the risk of injury and represents a safety
Warning risk during operation of the system, including danger to life!
Liability In the case of damage resulting from improper use and unauthorized interven-
tions, which are not provided in the Mobile Hydraulics Project Manual, any
liability claims for defects or other liability claims vis-à-vis Bosch Rexroth AG
become void.
If Projects 01 to 09 described in the Project Manual Proportional Valve Tech-

nology are carried out on training stands and with electrohydraulic components
that were not delivered by Rexroth, that is, products of competitors' make, any
defect or liability claims vis-à-vis Bosch Rexroth AG shall be void as well.
When using competitors' products, observe the safety notes

of the manufacturer and make sure that the components and
systems comply with currently valid EU Directives.
For this reason, commissioning is prohibited until it was estab-

lished that the electrohydraulic components and systems to be
Warning used meet the stipulations of all relevant EU Directives.
Note:
The required safety regulations, product information documents* and operat-
ing instructions must be handed over or be accessible to the trainee in their
latest issue.
In the description of Project exercises 01 to 07 in the Proportional Valve Tech-

nology Project Manual, the correct handling of hydraulic fluids is not referred to
in detail. Corresponding information can be found in the safety data sheet.
The correct handling of hydraulic fluids is dealt with in a separate chapter
in the following, which also describes potential hazards and precautions for
averting risks.
* Rexroth product information sheets are valid exclusively for hydraulic prod-
ucts, which are operated with hydraulic fluids based on mineral oil, unless
the use of other hydraulic fluids is expressly permitted in the operating
instructions.
Notes
Basic principles
principles of
ofproportional
proportionalvalve
valve technology 1 Bosch Rexroth AG I RE 00847/07.07
Basic principles of proportional valve technology

Pressure differential, valve opening, velocity
To be able to understand proportional hydraulics, some fundamental principles
must be known.
The flow through a valve and hence the actuator velocity depends on two
factors. These are the opening cross-section and the pressure differential
across this cross-section.
The larger the cross-section (A) and the higher the pressure differential (∆p),
the larger is the flow (q).
This applies by analogy also in the field of electrical engineering. The cross-
section corresponds to resistance (R), the pressure differential to voltage (U)
and the flow to electric current (I).
A descriptive example is to illustrate the relationship of cross-section, pressure

differential and flow.
Load 2 = 30 bar
Load 1 = 30 bar
Load 0 = 10 bar
∆
d = 5 mm
psys - pL = Dp → q
Load 0 100 - 10 = 90 bar 117 l/min
Load 1 100 - 40 = 60 bar 96 l/min
Load 2 100 - 70 = 30 bar 68 l/min
The valve opening is to correspond to a bore of d = 5 mm, the system pressure

is assumed to be 100 bar; the load acting on the cylinder and hence the load
pressure (pL) is changed with the loading.
The formula q ≈ f • A • ∆p can be used to approximately calculate the flow
in l/min ( A = d 2 • π / 4 ; f = 0, 68 ). A detailed computation depends on further
factors and conditions, which are not to be dealt with in detail at this point. For
hydraulic valves, the flow rates are measured, because calculations are very
difficult due to the flow situation and the geometry in the housing.
It can be seen that with increasing load, the ∆p, and consequently the flow
becomes smaller. In practice, this means that with the same valve opening a
cylinder without load moves faster than with load.
Basic principles of proportional valve technology 2 Bosch Rexroth AG I RE 00847/07.07
Structure and function
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Type 4WRA 6 ... -2X/
4/2 and 4/3 proportional directional valves are direct operated valves of sand-
wich plate design.
They are operated by proportional solenoids with central thread and detachable
coil.
The solenoids can be optionally controlled by external control electronics.
The valves basically consist of:

Structure – Housing (1) with mounting face
– Control spool (2) with compression springs (3 and 4)
– Solenoids (5 and 6) with central thread
Function – In the non-operated condition of the solenoids (5 and 6), the control spool
(2) is held by compression springs (3 and 4) in the central position
– Direct operation of the control spool (2) by energizing a proportional
solenoid, e.g. activation of solenoid "b“ (6)
→ The control spool (2) is shifted to the left in proportion to the electrical
input signal
→ Connection from P to A and B to T through orifice-type cross-sections
with progressive flow characteristics
– Deactivation of the solenoid (6)
→ The control spool (2) is brought again to the central position by the
compression spring (3). In this way, the function of the valve spool in the
de-energized condition is always clearly defined.
Spool Control lands are cut in the spools, with the help of which throttling cross-
sections with progressive flow characteristics can be adjusted steplessly in
dependence upon the stroke.
Standard spools are check spools (E) and spools A, B unloaded to T (W).
In the case of E-spools, all ports have a 15 % overlap in the central position.
This means that the control lands open only after a spool stroke of 15 %.
With W-spools, in the central position, ports A, B are opened via small lands
to T for unloading purposes, if, for example, pilot operated check valves are
installed in service lines A, B. Port P has a 15 % overlap.
Characteristic To obtain as high a resolution as possible, up to three different spools with

curves control lands of different sizes are available per valve size.
These control spools are dimensioned for certain nominal flows at a valve pres-
sure differential of 10 bar. For example, with a WRA6 valve with E07 spool, the
nominal flow is 7 l/min at a pressure differential of 10 bar. This value merely
serves to define the spool. At a higher pressure differential, the valve flow rate
is accordingly higher. For this reason, it is important to always observe the flow
values given in the diagrams of the technical data.
This is to be illustrated with the help of an example :

Flow q required for a certain cylinder velocity is 25 l/min, system pressure p
is 150 bar, load pressure pA is 100 bar. Consequently, the valve pressure dif-
ferential is (∆p) p - pA = 150 - 100 = 50 bar.
If an E07 spool was selected, only 15 l/min can be achieved at a pressure dif-
ferential (4) of 50 bar and 100 % valve opening. This means that the required
cylinder velocity cannot be achieved.
With an E30 spool, 25 l/min can already be achieved with a valve opening of
80 %, the remaining 20 % are useless. This would mean a poor resolution of
the valve stroke.
With an E15 spool, 25 l/min can be achieved at 98 %, and only 2 % are use-
less. This is a better resolution of the valve stroke. In this case, an E15 must
be selected. The better the resolution of the valve stroke, the easier to adjust
is the control.
Another example:
In this example, flow q is 10 l/min, the valve pressure differential is again
50 bar. If spool E30 was selected, 10 l/min is achieved at a valve stroke of only
53 %. With spool E07, it is achieved at a valve stroke of 80 %. Here, spool E07
must be selected.
For the engineering of circuits with proportional valves, it is always important to
know the pressure differentials across the valve.
When maintenance and repair work is carried out on systems, valves of differ-
ent nominal flows must not be mixed up. Otherwise, the system would move at
completely different velocities, even if the settings remained unchanged.
Characteristic curves (measured with HLP46, q = 40 °C ± 5 °C)

7 l/min nominal flow at 10 bar valve pressure differential 15 l/min nominal flow at 10 bar valve pressure differential
30/l/min nominal flow at 10 bar valve pressure differential
1 Dp = 10 bar constant
Dp = Valve pressure differential (inlet pressure pP

less load pressure pL less return flow
pressure pT)
Characteristic curves of a WRA6 proportional
valve
Types of con- Proportional valves can be controlled in two different ways,

trolling One type is "open-loop controlled" without feedback of the spool position, the
other is "closed-loop controlled" with spool position feedback by a position
transducer.
The WRA valve presented so far, is operated in the open-loop control mode.
This function is now to be dealt with in more detail.
The higher the current flowing through the solenoid, the greater is its force (F).
This magnetic force acts on the spool, which is loaded by the spring located
on the opposite side.
If the magnetic force is greater than the spring force, the spring is compressed
until a balance is obtained. As the current increases, the magnetic force be-
comes greater and the spring is compressed further. As the current is reduced,
it is the other way round. Because the spool stroke is always identical with the
spring travel, corresponding opening cross-sections are obtained on the control
lands.
An important factor for this principle is the precise matching of the magnetic
force with the spring constants, because otherwise, no defined opening cross-
sections can be achieved.
At this point, the problem of this principle becomes apparent.
If a part of the magnetic force is lost, e.g. due to increased friction, this force is
missing on the spring side, which will consequently perform a shorter stroke.
Thus, a smaller opening cross-section is available, which results in a smaller
flow. In practice, a cylinder would move at a correspondingly lower velocity.
Depending on the change in the friction situation of the spool, the cylinder
velocity changes as well.
Small flows require only small openings and hence lower magnetic forces. In
this case, friction has an even stronger effect.
It is easily conceivable what happens if contaminated oil is used, which strongly
increases friction.
To obtain a reliable proportional valve, the position of the spool in the housing
is measured by means of a position transducer and the result fed to a control-
ler. This controller increases the solenoid current until the required position in
the housing is reached. The controller can always work with the max. solenoid
current, if required.
The function of a closed-loop controlled system can be explained in a simplified
way in the following. The command value is provided by a machine control. It
corresponds to a certain valve opening in % or Volt (100 % = 10 V).
The actual value corresponds to the actual position of the spool in % or Volt.
The task of the controller is to achieve and maintain a system deviation of: com-
mand value – actual value = 0.
To this end, the controller issues a control output to the relevant solenoid.
The greater the difference between command value and actual value, the greater
is the control output.
The controller is continuingly active and corrects any deviation.
Should frictional forces occur, the controller increases the solenoid current ac-
cordingly until the difference becomes 0.
Friction, springs and forces acting on the spool have no influence on the func-
tion.
This principle offers some advantages:

1. Higher functional reliability
2. The proportional valves operates more dynamically and is more efficient
3. The required valve opening is exactly adhered to
4. The spool position can be measured for fault analysis and monitoring pur-
poses
Proportional directional valve with position transducer (7), type 4WRE 6 ... -2X/ ...
1 Housing
2 Control spool
3,4 Compression springs
X1, X2 Spring plates
5,6 Solenoids
P1,P2 Pole tubes
7 Position transducer
9 Sealed plug screw of the mechanical position transducer
adjustment element
11 Plug screw in the case of single-sided actuation
Electronics
In order to ensure optimum operation of proportional valves, special amplifiers
were developed for each valve series. These amplifiers can be designed as
Euro-card, module or integrated On-Board Electronics (OBE).
The general operating principle of the amplifiers is to be explained in the fol-
lowing.
Integrated On-Board Electronics (OBE)
Interface Integrated electronics (OBE) Valve
The electronics is located on the valve, thus forming a functional unit.

A power supply unit is supplied with 24 V and generates the required internal
voltages.
An analog voltage of ±10 V or a current of 4 - 20 mA is applied to the dif-
ferential amplifier. The valve opens proportionally to the value applied. The
analog signals must be generated by the machine control, e.g. a PLC. Further
possibilities of generating command values are command value cards, modules
and closed-loop control electronics.
The ramp generator can be used to adjust the gradient of the command values,
unless this was effected by means of analog signals. If the ramps are gener-
ated by the machine control, the setting of the ramp potentiometer should not
be changed.
The actual value is brought out for diagnosis purposes.
With the help of the zero point, the position of the spool at a command value
of 0 % can be adjusted. This is, however, only required in exceptional cases for
control purposes; for this reason, the zero point potentiometer setting should
not be changed.
In the case of undervoltage, the solenoid currents are switched off in order to
prevent uncontrolled movements.
The controller works as described before.
Amplifier cards (external electronics)
Simplified Power supply unit 1 provides all the required voltages.

functional External command values can be applied to two analog inputs 2, 3 in the form
description of voltage of ±10 V or current of 4 - 20 mA. This possibility is used, if, for ex-
ample, the command values are provided by a PLC.
If command value selection logic 4 is used, the command values on the card
can be adjusted by means of potentiometers W1 - W4. The set command val-
ues are activated with digital 24 V signals to command value call-ups. If several
command values are called up simultaneously, the command value with the
highest number becomes active.
Negative command values must be activated with inversion. This is required,
if, for example, the cylinder is to retract.
The ramp generator is used to adjust the gradient of the command values. The
gradient has an influence on the opening and closing speed of the valve, and
hence on the acceleration and deceleration of the moved machine.
Controller 17 receives the internal command value voltage and the voltage
value from the position transducer and outputs a voltage that corresponds to the
system deviation to current output stage 18, which generates the individual,
clocked solenoid currents up to 2.5 A. The solenoid current is clocked to approx.
5 kHz. Clocking allows a low-loss variation of the magnetic force.
Detailed functional description

Power supply The amplifier card is equipped with a power supply unit with switch-on current
unit [1] limitation, which provides all the internally required positive and negative supply
voltages. The switch-on current limitation prevents high switch-on current peaks
caused by smoothing capacitors in the current output stage.
Command value The internal command value signal is created from the sum (summation [6]) of
provision the external command value applied at differential input [2], at current input [3],
the called up signal [4] and the zero point offset [5] (zero point potentiometer
“Zw”).
The following is valid:
Standard Current Differential Command Direction of flow

values input input value test
socket
-100 % 4 mA -10 V -10 V P to B, A to T
0% 12 mA 0V 0V
100 % 20 mA 10 V 10 V P to A, B to T
0 1 mA** 0V
** If the current input is not connected, or in the case of a cable break on the
current command value line, the resulting internal command value signal cor-
responds to 0 %.
There is no changeover between current and voltage input. The inputs are per-
manently available (see terminal assignment).
Command Four command value signals "w1“ to "w4“ can be called up. The external com-
value call-ups mand value voltages (command values 1 to 4) are provided either directly by
[4] the regulated voltage outputs +10 V and –10 V or via external potentiometers.
If the command value sources are connected directly to the regulated volt-
ages, the command values can be adjusted by means of potentiometers "w1“
to "w4“. If external potentiometers are used, the internal potentiometers act as
attenuators or limiters.
Only one call-up is possible at a time. If several call-ups are made simultaneously,
call-up "1" has the lowest priority, call-up "4" the highest priority.
The currently active call-up is signaled by a yellow LED on the front panel.
Command The command value created internally from the input signals, command value
value inversion call-ups and zero point offset signal can be inverted by means of an external
[7] signal or jumper J1. The application of an external inversion is signaled by an
LED ("–1“) on the front panel.
Enable function The enable function is used to enable the current output stages and pass the
[8] internal command value signal on to the ramp generator. The enable signal is
indicated by an LED on the front panel. When the enable is granted, the internal
command value changes by the set ramp time (with any command value input).
A valve will therefore not open abruptly when activated.
Ramp genera- The ramp generator limits the gradient of the control variable. The ramp time
tor [9] is not shortened or extended by downstream jump functions and amplitude
attenuators. Jumper J2 can be used to set the ramp time is set to minimum
(< 2 ms) (ramp off).
External ramp time adjustment:
The internally set ramp time can be extended by means of an external poten-
tiometer. The setting can be verified at the test socket. In the case of a cable
break, the internal pre-setting becomes automatically valid.
Characteristic The adjustable characteristic curve generator serves to adjust jump heights and
curve generator maximum values separately for positive and negative signals to suit the hydraulic
[11] requirements. The actual path of the characteristic curve through the zero point
is not step-like, but linear.
Amplitude limi- The internal command value is limited to approx. ±110 % of the nominal
ter [12] range.
Oscillator [14] The oscillator generates the control signal for the inductive position trans-
ducer.
Demodulator The demodulator provides the actual value signal of the valve spool position
[15] from the position transducer signal. 100 % = 10 V
Position con- The position controller is optimized specifically to the relevant valve.
troller [17]
Current output The current output stage generates the clocked solenoid current for the pro-
stage [18] portional valve. The solenoid current is limited to 2.5 A to 2.8 A per output. The
output stage outputs are short-circuit-proof. The output stages are de-energized
in the event of an internal fault signal or missing enable.
Fault detector Monitoring of the position transducer cable for cable break and short-circuit on
[19] the primary side as well as overcurrent of the output stage.
[ ] = Cross-reference to the block circuit diagram

Ramp →
The ramp prolongs the rise of the command value in order that the valve is
closed or opened more slowly.
This is to be illustrated by an example:
The command value is changed from 0 % to 100 % in 2 ms; without a ramp,
the valve would open abruptly and the machine accelerate equally abruptly. If
the command rises now in 500 ms from 0 % to 100 %, because the ramp was
set accordingly, the valve opens more slowly and the machine is softly acceler-
ated. A ramp time of 250 ms can improve the machine behavior significantly in
many applications.
This depends on the design, the masses and velocities.
If the ramp time is set much too long, it may happen that, for example, limit
switches are passed too far. In this case, the valve closes only very slowly
after the limit switch was activated, and the cylinder continues to move during
this time.
Signal sequence
Now that the functions of the individual components are know, they are to be
joined together to form a system. The block diagram is to represent the flow of
signals.
Signal Machine Command value Electrical Hydraulic Hydraulic

encoder control generation gain gain movement
Command
value Controller Directional Cylinder
Relay
potentiom- Output valve or
PLC
eter, ramp stage ∆p motor
generator
Digital signal Analog signal
External encoders such as switches, push-buttons, limit switches, pressure

switches issue signals to the machine control, where they are logically linked.
This can be accomplished with relays or programmable controls.
A digital signal from the control is used to call up a command value.
According to the command value and ramp settings, an analog signal is fed to
the valve controller and then to the output stages, in which it is amplified until
a solenoid current of up to 2.5 A is reached. In the solenoids the current gen-
erates a force, which shifts the directional valve spool. The proportional valve
converts an electric current analogously into a hydraulic oil flow.
Depending on the hydraulic conditions such as the pressure differential the
actuator will perform a movement and actuate the machine.
Symbol
The symbol of a proportional valve differs from the symbol of an on/off valve in
the following features:
Uninterrupted lines (2) are drawn above and below the control element (1),
which symbolize stepless adjustability.
The actuating solenoids (3) are drawn with an arrow (4), which stands for the
adjustability of the solenoid current.
In the case of valves with feedback of the spool position, the symbol of a posi-
tion transducer (5) is provided additionally on the solenoid.
If the electronics is mounted on the valve, the symbol for the amplifier (6) is
shown on the solenoid.
Proportional directional valve with integrated electronics
5 2 1 4
6 3
Pressure control with integrated electronics
1 2 4 6
3
Analog command value module VT-SWMA-1

Proportional valves with integrated electronics (OBE) require analog signals,
+/- 10 V or 4 - 20 mA, as control signal.
The valve opens in proportion to the intensity of the control signal. 10 V corre-
sponds to a valve opening of 100 % . The signal can be continuously changed
and the valve opening must follow without delay.
This technology can be used to continuously control a machine velocity.
Electronics such as position controllers, position transducers, solenoid current
regulators, etc., which are required for operating the valve, can be provided
externally on an amplifier card in the control cabinet or internally on the valve.
The electronics is optimized by the manufacturer and cannot be changed by the
user. On some OBE the valve zero point and the valve ramp can be adjusted.
Such adjustments are, however, only required in special cases. If the control
signals are generated by a control, no settings are necessary on the valve; on
the contrary, this could cause malfunction. Therefore, never make any settings
on the valve electronics, unless you have the required knowledge.
Analog control signals can be generated by various sources.

The simplest possibility is, for example, a manually operated potentiometer.
In PLC controls with analog outputs, analog control signals can be pro-
grammed.
Controllers output the continuously changed actuating signals, which form the
control signals for the valves.
If a control cannot generate analog signals, for example a relay control or a PLC
with digital outputs, special electronic circuits are required to generate analog
signals. These circuits convert digital switching signals into analog signals.
Analog command value modules are electronics, with are optimized to suit the
requirements of hydraulic drive technology. Command value modules can be
used to adjust rapid and creep speed sequences with separate ramps for ac-
celeration and deceleration for both directions of movement.
The relevant direction and velocity are called up digitally by the machine control
(PLC, relay, switch).
On the command value module, the velocities are adjusted by means of com-
mand value potentiometers.
Acceleration and deceleration rates are adjusted by means of ramp potenti-
ometers.
The analog signals from the command value module are converted into a cor-
responding valve opening by power electronics on the valve.
In such an arrangement, command value generation and valve electronics are
separated.
Alternatively to the command value module, analog and digital command value
cards can be employed.
Another method is the common arrangement of command value generator and
valve electronics on an amplifier card.
In industrial practice, the separate arrangement of command value generator

and valve electronics is now the most common solution.
- Valve and electronics form a functional, tested unit with a standard +/- 10 V
or 4 - 20 mA interface.
- No amplifier card needs to be installed in the control cabinet.
- Only one 7-pin cable is required to the valve when compared with 3 cables
for an external amplifier card.
- The command value can be generated flexibly and independently of the
valve.
- This arrangement is less susceptible to faults.
Notes
Operation of the command value module
Front of the VT-SWMA-1 command value module
Potentiometers "w1-4“ are used for adjusting the command values and hence
also the cylinder velocities. The set values are activated by means of command
value call-ups. Command values "w1“ and "w2“ are positive, whereas "w3“ and
"w4“ are negative. In this way, a cylinder can, for example, extend with "w1“ and
"w2“ and retract with "w3“ and "w4“.
A ramp is assigned to each command value "w1“ → "t1“, "w2“ → "t2“, etc.
This means that when command value "w1“ is active, only ramp "t1" is also
activated.
Ramp "t5“ is active, when no command value is active.
This is to be illustrated by means of an example:

A cylinder is to extend at rapid speed and, after having reached a certain posi-
tion, at creep speed and stop at a further position.
Command value "w1“ is activated for rapid speed, command value "w2“ for
creep speed. When "w1“ is active, "t1“ is active as well. Consequently, the
acceleration for starting up the cylinder can be adjusted with the help of ramp
"t1“. Upon the switch signal "creep speed", command value "w2“ and ramp
"t2“ become active. The creep speed is adjusted via command value "w2“, the
associated deceleration with ramp "t2“. After the switch signal "halt" command
value "w2“ is switched off and, because no command value is active at that
time, the deceleration is adjusted by means of "t5“ .
"4-Q“ is used for activating quadrant recognition.

4-quadrant operation means retracting, extending and accelerating, decelerat-
ing, which is required for motion sequences with cylinders.
2-quadrant operation means accelerating and deceleration in only one direction;
this is applicable for motors with only one direction of rotation.
With the help of quadrant recognition all of the 4 possible changes in veloc-
ity can be adjusted optimally and individually. This is a very useful function for
motion sequences.
In this mode, ramps "t1 - 4“ are no longer firmly assigned to the command values,
but to polarity and signal direction. The electronics recognizes the direction of
the new command value and selects the corresponding ramp.
"t1“ → accelerating - extending
"t2“ → decelerating - extending
"t3“ → accelerating - retracting
"t4“ → decelerating - retracting
"t5“ → decelerating when "4Q“ and command values are switched off,
Quadrant recognition
When quadrant recognition [8] is activated, the electronics automatically rec-
ognizes polarity [9] and the change (up/down) [10] of the control output and
assigns a ramp time to the current signal state.
Polarity of the Signal changes

Ramp time
control output towards
0% Maximum
t1 + Maximum value
value (+)
Maximum
t2 + 0%
value (+) 0%
0% Maximum
t3 - Maximum value
value (-)
Maximum
t4 - 0% value (-) 0%
e.g. emergency stop

The function is to be illustrated with the help of an example:
A cylinder is to extend and retract. The acceleration rates are to be high, and
decelerations are to be realized softly. Different values are therefore required
for extending and retracting.
"w1“ is the command value for extending, "w3“ the command value for retract-
ing. The command values are used for adjusting the velocity.
The acceleration of the cylinder in the direction of extending is adjusted with "t1“.
The deceleration of the cylinder in the direction of extending is adjusted with "t2“.
The acceleration of the cylinder in the direction of retracting is adjusted with "t3“.
The deceleration of the cylinder in the direction of retracting is adjusted with "t4“.
In this way, all changes in the movement can be adjusted separately.

"INV“ can be used for changing the polarity of the command values.
This is required, if more than 2 command values are required for one direction
of movement. If, for example, a third velocity is required for extending, it can be
adjusted by means of "w3“. "w3“ has a negative polarity. In order to be effec-
tive in the direction of extending, the polarity must be changed to positive. To
this end, "w3“ is to be activated together with "INV“.
Amplitude attenuator "G“ only acts on the differential input (terminal 4,5). The
amplitude attenuator can be used to reduce the voltage signal applied at the
differential input to a certain value. Example: 10 V is applied at the differential
input. The amplitude attenuator reduces the signal to 7.5 V. Consequently, the
valve opens to only 75 %. It is therefore possible to limit the maximum velocity
with the help of the amplitude attenuator, if the command value signal is provided
via the differential input from another open or closed-loop control. This function
is particularly important in closed-loop controls, if a maximum cylinder velocity
must not be exceeded.
"G" should normally be set to 110 % (right-hand limit stop).
Zero point balancing "Z" can be used for adjusting a command value up to +/-
3 V without a command value being activated or a signal being applied at the
differential input. This is useful for commissioning purposes.
The command value should always be 0 V, when no command value is activated
or no signal is present at the differential input. If that is not the case, the com-
mand value must be set to 0 V with the help of "Z".
The voltages for command values "w" and ramps "t" can be measured at the
test sockets. Only the latest values are present at the test sockets.
To be able to measure a set value, the associated command value or ramp must
be activated by means of a command value call-up.
For the command valves, 10 V corresponds to a valve opening of 100 %.
The following is valid for the ramps:

Note on the adjustment and measurement of the ramp time.
It is recommended that 4-quadrant recognition be switched off and the call-ups
be made when the ramp time potentiometers are to be adjusted.
Value at test socket "t“ 3 2

5 1 0.5 0.3 0.2 0.1 0.05 0.03 0.02
Ut in V
Current ramp time 20 33 50 100 200 333 500 1000 2000 3333 5000
(±20 %), t in ms
The following is valid: t = 100 V ms Example: Ut = 5 V

Ut
provides: t = 100 V ms = 20 ms
5V
It can be seen from the table that the voltage is inversely proportional to the
ramp time.
In most of the cases, the ramps are not set on the basis of time, but the ma-
chine behavior. Thus, the voltage measured mainly serves as test voltage, e.g.
for documentation purposes.
Notes
Safety notes 1 Bosch Rexroth AG I RE 00847/07.07
Fundamental safety notes

In order that potential risks for plant and machinery can be recognized, safety
regulations, product documentation and operating instructions must be ob-
served.
The trainer must make the required documents available to the trainee. When
competitors' products are used, the safety notes of the relevant manufacturer
are applicable, and it must be ensured that the components and systems comply
with currently valid, relevant EU Directives.
Commissioning is therefore prohibited until it was established

that the electrohydraulic components and systems that are to
Warning be used, conform with all relevant EU Directives.
Fundamental,
general safety
notes
Observe Warning
• danger signs and safety notes on the machine

• instructions, which prescribe the behavior during operation in order to prevent
accidents and health damage and must be prepared by the operator/employer
on the basis of, for example, regulations for the prevention of accidents,
• operating instructions, which ensure the proper use of the hydraulic system
in accordance with its intended purpose.
The operating instructions are intended for information purposes

and for the prevention of risks when hydraulic components
are being installed in a system - in this case mounting of elec-
trohydraulic components on the training stand -, and include
information and notes on transport, storage and maintenance
(inspection, servicing, corrective maintenance) of the hydraulic
system.
Only when the operating instructions are strictly observed can
accidents and damage to property be avoided and the trouble-
free operation of the hydraulic system be ensured.
Moreover, observing the operating instructions helps to:
• reduce downtimes and repair costs
• prolong the service life of the hydraulic system.
Hydraulic oil based on mineral oil is water-endangering and inflammable. It

may only be used when the corresponding safety data sheet is available and
all precautions prescribed therein were taken.
The hydraulic system may only be operated when in technically perfect condi-
tion.
The use for the intended purpose, performance data and operating conditions
must not be changed.
Protective equipment / components must not be rendered inoperable, e.g. by

bridging limit switches, valves or other control components.
If protective equipment must be bridged to allow servicing work to be carried

out, precautions must be taken to ensure that no dangerous situation can arise.
The higher-order machine operating instructions must be observed.
Adjustment features on components may only be operated or changes to

programmable control systems made exclusively by authorized personnel within
the framework of the intended use of the hydraulic system.
In the case of an emergency, fault or other irregularities:

• hydraulic systems must be switched off and the main circuit breaker be se-
cured against restarting,
• the danger zone must be fenced off in order that nobody can enter the danger
zone unknowingly or in an uncontrolled manner,
• immediately inform the responsible specialist personnel.
Uncontrolled access by external persons to the direct operating area of the hy-
draulic system is prohibited (even in case that the hydraulic system is at rest).
Note:
These are the fundamental safety regulations that must be observed for every
project task.
Effects of air Air can be present in hydraulic oils in the following forms: as dissolved air (in-
in the oil visible), as surface foam (visible), and as undissolved, dispersed air (visible).
While dissolved air and minor surface foam hardly show any adverse effects,
dispersed air can cause severe problems. Since the oil contains very small air
bubbles, which are finely dispersed and can rise to the surface only very slowly,
the following troubles can occur:
• Uneven or jerky movements of hydraulic spools, vibration in the system due
to increased compressibility, changed actuating times of servo-valves
• Pump noise
• Damage to pumps, lines and seals caused by cavitation
• Accelerated aging of the oil
• Micro-diesel effect, a form of thermal cracking due to high temperatures in
compressed air bubbles
To prevent undissolved air in the oil, the following must be observed: No leak-
age in the system on the suction side, optimum storage tank size, installation
of baffles in the oil storage tank, favorable design of the suction system without
throttling points, sufficient oil level, low oil circulation rates, immersed pumps
instead of great suction heights.
Environmental Hydraulic systems are closed systems. When hydraulic systems are used
aspects properly, hydraulic fluid does therefore not get into the environment. Care must
be taken that power units are leak-free and maintenance/repairs are carried
out in due time. Especially hydraulic hoses and hose connections must be
intensively observed and inspected. Oil changes must be made properly and
thoroughly; waste oil must be disposed of in accordance with all relevant legal
stipulations.
Safety aspects Hydraulic fluids based on mineral oil are water-endangering

and inflammable. Hydraulic fluids may only be used, if the cor-
Danger responding safety data sheet of the manufacturer is at hand and
all precautions prescribed therein are observed.
If leakage on the hydraulic product can lead to the contamina-
tion of water and soil, the hydraulic product must be placed in
a suitable oil drip tray.
Filtration An essential precondition for the trouble-free operation of a hydraulic system

is the flawless condition of the hydraulic fluid, for one of the main causes of
failure of hydraulic components was and still is contamination. The sketch be-
low shows various types of contaminaion that can lead to contamination of the
hydraulic fluid.
1 External contamination
2 Installation + repair
3 Fresh oil
4 Abrasion in the pump
5 Abrasion of seals
Sources of contamination
Classification Technical data sheets include notes on the assessment of solid particle con-
tents in hydraulic fluids with the help of classification systems (standardized
cleanliness classes).
The most common standards today are NAS 1638 (National American Standard)
and ISO DIS 4406.
The indication of the filter rating in µm is no longer common practice today, but
is often applied when circuit diagrams are created.
Note:
The comprehensive subject of filtration and maintenance is not dealt with in
detail in the Project Manual Proportional Valve Technology. A specific project
for a later, extended issue is in preparation.
Notes on the topic of filtration can be found in information sources such as
data sheets, operating instructions and technical books, which are referred to
in the Project Manual Proportional Valve technology.
Project exercises for propotional valve technology 1 Bosch Rexroth AG I RE 00847/07.07
Project order: Modernization of a hydraulic press
An old hydraulic press, which is still in good shape in terms of the

mechanics, is to be modernized.
The objective of the modernization is:
1. to increase productivity
2. to become more flexible with regard to product changes
3. to achieve better accuracy
4. to automate the press control
The press is used for deep-drawing kitchen sinks of different designs.

The sequence of a press is:
• Initial position ram up, press open
→ Rapid speed downwards
→ Decelerating
→ Slow pressing
→ Pressure holding
→ Decompression
→ Rapid return
The operating modes are setup mode and production mode.

Up until now, the press has been operated semi-automatically by a press opera-
tor and a feeder.
It was controlled by means of a linkage with manually operated hydraulic direc-
tional valves.
The pressing pressure was adjusted by means of chain-operated pressure relief
valves.
Rapid speed was initiated by the press operator using a lever.
Decelerating and the pressing velocity were adjusted by means of cams and a
roller-operated deceleration valve.
Decompression and return were also initiated by the press operator by means
of levers.
The quality of the produced sinks depended, of course, strongly on the experi-
ence and routine of the press operator. In the case of a product change and
hence a die change, the press had to be newly run in. Moreover, the quality
produced by the individual press operators also showed fluctuations.
Now, the order is to realize a fully automatic control for the hydraulic press.
Machine controls today are electrical, and for this reason, only electrically ad-
justable valves and electrical sensors are used.
Components:
- Proportional directional valve 4WREE6E08/2X
- Inductive limit switch
Safety aspects
Safety and the economic use of resources are essential demands that are placed
on modern plant and machinery and serve to protect people. These two require-
ments have in common that they have to be taken into account as early as pos-
sible, that is, at the product concept stage. Only in this way can optimized and
low-priced solutions be found. Safe machines with low consumption demonstrate
that the manufacturer masters his processes; they are a quality feature.
In order that hazards to plant and machinery can be recognized, safety regu-
lations, product information brochures and operating instructions must be
observed. Corresponding notes on handling electrohydraulic components and
systems of Bosch Rexroth can be found in:
• General product information on hydraulic products
RE 07008/02.05
• Operating instructions for hydraulic systems
AB 01-01.02
• Hydraulic cylinders of tie rod/mill-type design (operating instructions)
RE 07100-B/10.04
• Operating instructions DS4 – 1X
RE 00225-B/05.05
The safety notes and product information in the above documentation are ex-
clusively valid for Bosch Rexroth hydraulic products.
Only if these operating instructions, safety notes and product information are
observed can the trouble-free operation of Rexroth products be ensured.
The present Project Manual Proportional Valve Technology includes warning

notes, which precede instructions for activities that involve a risk of personal
injury or damage to property. The described precautions for averting risks must
be taken.
Conventions
This symbol refers to imminent danger that, if not avoided, can
lead to severest injuries or death.
Warning
This symbol refers to a potential risk, which can lead to light or

serious injuries or damage to property.
Caution
This symbol refers to supplementary information.

Note:
The electrohydraulic components and systems described in this Project Manual
are technical equipment, which is not intended for private use.
The use for the intended purpose also includes that the safety regulations,
product information and operating instructions described in the following are
read and understood.
Qualification of Installation, commissioning and operation, disassembly, upkeep and maintenance

personnel require fundamental knowledge of mechanics and electrohydraulics as well as
the knowledge of related technical terms. In order to ensure operational safety,
these activities may only be carried out by a corresponding specialist or by an
instructed person under the supervision of a specialist.
A specialist is, who, due to his/her professional training, his/her knowledge and
experience and the knowledge of relevant regulations, can asses the duties
assigned to him/her, recognize potential risks and take suitable precautions. A
specialist must observe relevant technical rules.
Consequently, this means that the trainer must point out potential risks to the
trainees and provide information of how to avert such risks.
Work carried out improperly on electrohydraulic components

and systems involves the risk of injury and represents a safety
Warning risk during operation of the system, including danger to life!
Liability In the case of damage resulting from improper use and unauthorized interven-
tions, which are not provided in the Project Manual Proportional Valve Tech-
nology, any liability claims for defects or other liability claims vis-à-vis Bosch
Rexroth AG become void.
If the Projects 01 to 09 described in the Project Manual Proportional Valve Tech-

nology are carried out on training stands and with electrohydraulic components
that were not delivered by Rexroth, that is, products of competitors' make, any
defect or liability claims vis-à-vis Bosch Rexroth AG shall be void as well.
When using competitors' products, observe the safety notes

of the manufacturer and make sure that the components and
systems comply with currently valid EU Directives.
For this reason, commissioning is prohibited until it was estab-

lished that the electrohydraulic components and systems to be
Warning used meet the stipulations of all relevant EU Directives.
Note:
The required safety regulations, product information documents* and operat-
ing instructions must be handed over or be accessible to the trainee in their
latest issue.
* Rexroth product information sheets are valid exclusively for hydraulic prod-
ucts, which are operated with hydraulic fluids based on mineral oil, unless
the use of other hydraulic fluids is expressly permitted in the operating
instructions.
Notes
Project 01: Moving a cylinder
with the help of a potentiometer 1 Bosch Rexroth AG I RE 00847/07.07
Project 01: Moving a cylinder with the help of an external po-

tentiometer for the provision of a command value 01
Project definition
For commissioning the machine control, which is still unknown to us, it should
first be moved carefully by hand. In this way, the behavior of the hydraulic ma-
chine control can be understood.
Of particular interest is the relationship between the command value and the
cylinder velocity.
Fig. 01.01 Section of a 4WREE6 proport. directional valve with integrated electronics OBE
Project tasks
• Testing of the valve function by measuring the command value and the actual value
• Determining the command value voltage for the start of movement
• Testing of polarities; with positive command values the cylinder must extend
• Determining the relationship between cylinder traversing time and command
values
Project steps
01
• Informing: In which condition is the machine? What exactly is to be car-
ried out?
• Planning: Select and read documents for information.
• Deciding: Selection of components.

Where are the components and measuring points?
How have the components to be connected to each other
(hydraulically and electrically)?
• Executing: Preparation of sketches of hydraulic and electrical circuit

diagrams and selection of the required drive elements and
accessories with short description.
• Checking: Is the polarity correct?
• Evaluating: How does the system behave?
Notes
Hydraulic circuit diagram

01
Fig. 01.02 Hydraulic circuit diagram

Electrical block circuit diagram

01
Command/actual
Command value provision Connection panel value display
Inputs Output Inputs Outputs Display 1

Supply
Command value Command value ±10 V Signal
Actual value
0V ⊥ Reference
±10 V Signal ±10 V (F)
24 V (D) ± 10 V Display 2
⊥ Reference ⊥ Reference (C) ±10 V Signal
(E) ⊥ Reference
Supply Valve ⊥ Reference
BPS 5.2
(B) 0 V Supply
(A) 24 V BPS 21.0 0V
+ 24 V
BPS 6.1
0V
+ 24V
Fig. 01.03 Electrical block circuit diagram
Fig. 01.04 Command value source/connection panel/command/actual value display

Component selection with parts list

01
Item Qty Component designation Type designation Symbol
1.0 1 Hydraulic cylinder ZY1.7
4/3 proportional directional

1.1 1 valve with load pressure DW40E-D.
valve
1.2 1 Pressure relief valve DD1.1N
1.4 1 Check valve DS 2.1
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection
1 Hydraulic hose VSK1. N-W
Table 01.01 Parts list for hydraulic circuit diagram Fig. 01.02
Item Qty Component designation Type designation
1 Command value module BPS 20.0
1 Command value source BPS 5.2
1 Connection panel of integrated electronics BPS 21.0
1 Distributor BPS 13.1
1 Command value/actual value display BPS 6.1
Stopwatch, 2 mm screw driver,

1
Allan key set
Table 01.02 Parts list for electrical block circuit diagram Fig. 01.03
Component arrangement
01
Fig. 01.05 Recommended component arrangement with component designations for parts list Table 01.01 and hydraulic
circuit diagram Fig. 01.02
Note:
The designations of components in the parts list and the component arrange-
ment are Rexroth-specific designations. Also the grid arrangement is Rexroth-
specific and adapted for use on the DS4 fastening grid.
Safety notes
01
To ensure the operability of plant and machinery, and con-
sequently to allow the recognition of potential risks, safety
regulations must be observed before and during the execution
of the order. Relevant sources of regulations are given in the
introduction of the present manual.
If work on electrohydraulic components is carried out improperly,
risks of injury and a safety risk during can arise during operation
Warning of the system, including danger to life.
Before starting work on the training stand, check that the elec-
trical ON/OFF switch on the hydraulic power unit is pressed in,
Caution i.e. that the system is switched off. Use the system pressure
gauges to check that the system is depressurized.
Hydraulic systems can store residual energy also after having
been disconnected from any energy source. This residual energy
must be discharged without any risk, e.g. by opening by-pass
or operating directional valves.
Execution of the order

Demands placed on the control:
The hydraulic circuit is to be set up so that the cylinder can be extended and
retracted by means of a 4/3 proportional directional valve. The cylinder must
extend with positive command values. The system pressure is to be limited.
Note for trainers:

The command value polarity for opening the valve is defined in data sheet
RE 29061 on page 8.
A positive command value corresponds to P→A and B→T, which results in
the fact that the cylinder piston side must be connected to A. The trainees
are to understand this with the help of the data sheet and implement it in the
circuit diagram.
Set the circuit up by following the steps below:

01
1. Hydraulic control
Prepare a circuit diagram and parts list in order to meet the requirements.
Mount the hydraulic components on the hardware trainer according to the
circuit diagram and connect them using hoses. To connect pressure gauges
with measuring line DZ1.4, use pressure hoses DZ 25.1. Tighten the pres-
sure gauge measuring lines at the relevant measuring point of the pressure
hose hand-tight.
Check the correct and tight connection of components with pressure hoses
by turning the hoses.
2. Electrical control
The electrical control must be set up so that proportional valve 4WREE6
DW40E-D can be operated with command value source BPS5.2. The com-
mand value and actual value are to be measured and displayed.
Prepare a circuit diagram in order to meet the requirements. Set up the pre-
pared circuit. Determine measuring points.
The yellow sockets are exclusively provided for a signal voltage

of +/- 10 V; never connect them to 24 V. This can cause damage
Caution to electronic components.
3. Testing the valve function

Switch the control voltage on. Hydraulic pressure is not yet required; for this
reason, the pump is not switched on and the by-pass valve is open. Gener-
ally, when taking voltage measurements, the signal (+/-10 V) must always be
measured against a reference (^).
The measuring points used on the BPS 21.0 are sockets D (+/-10 V), E (^)
for the command value, and F (+/-10 V), C (^) for the actual value.
Run command values from 0 V to 10 V with positive and negative polarity
with the help of command value source BPS 5.2.
Observe the voltages on command/actual value display BPS 6.1.
The command value and the actual value must always have the identical value
+/- 0.02 V.
If the actual value deviates significantly from the command value, a fault must
be present in the valve or valve electronics.
Causes of faults:
01
• Actual value always 0 V
→ Valve electronics defective, no voltage supply
• Actual value always e.g. 2.7 V
→ Valve spool jammed in the housing
• Actual value gets stuck at e.g. 3.1 V
→ Valve spool blocked at 3.1 V
Integrated valve electronics are factory-set on test rigs and must

not be modified by the user.
Caution
Adjustments of the integrated valve electronics on the system
are necessary in exceptional cases only and require special
knowledge.
Unqualified modifications can lead to unexpected valve char-
acteristics.
Fig. 01.06 Integrated electronics

4. Moving the cylinder by providing a command value

01
At a command value of 0 V the cylinder must be at rest.
Otherwise, the setting of the proportional valve must have been changed.
First set the command value input to 0 V and turn the potentiometer to 0 V,
otherwise, the cylinder starts to move as soon as pressure is built up in the
system.
Fully unload the system pressure relief valve.
Fully unload the load pressure relief valve.
Switch on the hydraulic pump and the control voltage.
Close the by-pass valve.
Check the hydraulic circuit for leakage.
Set the pressure relief valve to 20 bar.
Use command value source BPS5.2 to slowly increase the command value
from 0 V with positive polarity, and observe, at which value the cylinder starts
to move.
Note this command value.
Slowly increase the command value further while observing the cylinder
velocity.
Reverse the cylinder's direction of movement with the help of the +/- polarity
switch.
With positive values the cylinder must extend.
Note for trainers:

The movement starts at approx. 1.2 V = opening of 12 %.
At an opening of 12 % leakage has reached an amount at which a clear cyl-
inder movement can be observed.
The valve overlap is 15 %; at this value, the control lands are opened. Minor
deviations can be traced back to housing tolerances.
The start of movement is not a creeping movement, but a clearly visible move-
ment; this is, of course, a subjective perception, which also results in tolerances
of the relevant values. For this reason, exact and reproducible values must be
measured by means of measuring instruments.
If a cylinder does not extend with positive values, hoses A and B were ex-
changed or the polarity of the command value input (D, E) for the valve was
reversed.
Also observe the correct polarity on the command/actual value display.
The measuring points for the command value are the output sockets of the
command value source, that for the actual value the test sockets "actual value"
on operator module BPS 21.0.
To get a grasp of the relationship of command value and cylinder velocity,

01
measure the extending times of the cylinder over the entire stroke using the
stopwatch.
Set the system pressure to 50 bar on the pressure relief valve.
The load pressure relief valve remains fully unloaded.
Increase the command values in 0.5 V increments
The starting position of the cylinder is the fully retracted position, the end
position is the fully extended cylinder position.
After completion of practical work, switch the hydraulic pump

on the training system off! Open the proportional valve again
Caution in both directions +/- to depressurize the working line and the
cylinder. Set the pressure relief valves to minimum pressure.
No pressure gauge may indicate a pressure.
Notes
Measured values
01
Command value Traversing time Velocity
1.5 V 20.0 s 20 mm/s
2.0 V 6.6 s 61 mm/s
2.5 V 4.0 s 100 mm/s
3.0 V 2.7 s 148 mm/s
3.5 V 2.0 s 200 mm/s
4.0 V 1.8 s 220 mm/s
4.5 V 1.6 s 250 mm/s
5.0 V 1.6 s 250 mm/s
5.5 V 1.6 s 250 mm/s
Table 01.03 Table of measured values
Diagram 01.01 Command value/velocity
Note for trainers:

The velocity behaves almost linear in relation to the command value. The control
spools are provided with circular lands. The pressure differential across the
valve also has an influence, because it is not constant.
From a value of approx. 4.5 V on, the velocity does no longer increase, because
the displacement of the pump limits the possible max. velocity.
At identical command values, the cylinder extends faster than it retracts; this
depends on the different pressure differentials during extending and retracting.
This will be dealt with in more detail in a later project.
Evaluating the work results

01
I. At which command value has the cylinder noticeably performed a move-
ment?
At a command value of 1.2 V the cylinder moved noticeably.
II. Why does the cylinder not yet start to move at 0.5 V?
The spool has a 15 % overlap in the housing.
III. How did the cylinder velocity change in relation to the command value?
As the command value increases, the cylinder velocity rises linearily.
IV. What limits the max. cylinder velocity and from which command value
on?
The max. velocity is limited by the max. displacement of the pump.
This starts at 4.5 V.
V. What determines the cylinder's direction of movement?

The polarity of the command value determines the direction of flow in the
valve and thus the direction of movement.
Project/trainer info
In Project 01 basic knowledge is to be imparted of the behavior of proportional
valves in a practical setup.
The project order is the first part of the general project "press modernization“
and represents the first step of commissioning.
In the practical setup, the following knowledge is to be imparted:
• Testing the valve function by measuring command value and actual value
• Knowledge of measuring points
• The amount of the command value determines the cylinder velocity.
• The polarity determines the cylinder's direction of movement.
• The cylinder only starts to move notieably at approx. 1.2 V due to the positive
valve overlap.
Notes
01
Project 02: Traversing a cylinder
with a command value module 1 Bosch Rexroth AG I RE 00847/07.07
Project 02: Traversing a cylinder with command value mod-

ule SWMA1 as command value source
02
Project definition
For commissioning the machine control, which is still unknown to us, the latter
is to be tested for function first. During this, trainees will be made familiar with
the signal flow and function of command value module BPS 20.0.
Fig. 02.01 Command value module SWMA1
Project tasks
• Activation of a command value with a digital signal
• Adjustment of the command value voltage on the command value module
• Testing of polarities
• Measurement of the command value voltage at the test sockets
Project steps
• Informing: In which condition is the machine? What exactly is to be car- 02
ried out?


diagrams and selection of the required drive elements and
accessories with short description.
Notes

02


+ 24V
3
1
3
2
02
S1 S2
4 4
Command value module
Inputs Outputs
Comm. value Measurands
Call-up 4 Comm. value w
Call-up 3 Reference ⊥ Comm./act.display
Call-up 2 Ramp time t
Call-up 1 Reference ⊥ Connection panel Display 1
Inversion ± 10 V signal
Inv. Control Inputs Outputs ⊥ reference
Differential output Comm. Val. Act. value Display 2
input ±10 V ± 10 V (D) (F) ± 10 V ±10 V signal
± 10 V Reference ⊥ ⊥ ref. (E) (C) ⊥ ref. ⊥ reference
⊥ reference Supply Supply
Ramp 0V (B) Valve 0V
4Q + 24 V (A) BPS 21.0 + 24 V
Supply BPS 20.0 BPS 6.1
0V
+ 24 V
0V
+ 24V
Fig. 02.04 Command value module/connection panel/command/actual value display


02

valve
1.4 1 Check valve DS 2.1
Pressure gauge with

0.1-0.3 3 Dz1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection
S1-S3 1 Switch and push-button BPS 7.4

1
Allan key set
02
Note:
Safety notes
To ensure the operability of plant and machinery, and con- 02
risks of injury and a safety risk during can arise operation of the
Warning system, including danger to life.

retracted using a 4/3 proportional directional valve. With positive command
values the cylinder must extend. The system pressure is to be limited.
Note for trainers:

The command value module is described in data sheet RE 29902.
On the basis of this data sheet, the trainees are to make themselves familiar
with the function of digital call-ups and command value settings and apply this
knowledge in a circuit diagram. Moreover, the position and function of control
and indicator elements is to be taken from the data sheet.
All of the ramp potentiometers should be set to their left-hand limit stop, be-
cause the ramp function will only be dealt with in later projects.
02
circuit diagram and connect them using hoses.
To connect pressure gauges with measuring line DZ1.4, use pressure hoses
DZ 25.1. Tighten the pressure gauge measuring lines at the relevant measur-
ing point of the pressure hose hand-tight.
The electrical control must be set up so that proportional valve 4WREE6
DW40E-D can be operated using command value module BPS 20.0.
Command value "w1" is called up using an S2 switch.
The inversion is called up using an S1 switch.
The command value and actual value are to be measured and displayed.
Prepare a circuit diagram in order to meet the requirements.
Set up the prepared circuit. Determine measuring points.

3. Testing of the command value module function

Switch the control voltage on. Hydraulic pressure is not yet necessary; for
this reason, the hydraulic pump is not switched on and the by-pass valve is
open.
Run command value "w1" from 0 V to 10 V with positive and negative polarity
using the command value module.
The command value must be activated with S2 "call-up 1“.
To change the polarity, activate the call-up "inversion" with S1. Measuring
points are w, ┴ on command value module BPS 20.0 for the command value,
and F(+/-10V), C(┴) on BPS 21.0 for the actual value.
When no command value is activated, the command value must be 0 V.
If a value is displayed, potentiometer "Z" must have been improperly
trimmed.
In this case, use "Z" to set the command value to 0 V.
4. Traversing the cylinder with the help of the command value module
First set command value "w1“ to 0 V, otherwise, the cylinder moves at an
undefined velocity as soon as "w1" is activated with S2.
02
Fully unload the pressure relief valve.
Unload the load pressure valve.
Switch on the hydraulic valve and the control voltage.
Inspect the hydraulic circuit for leakage.
Operate switch "S2“ to call up command value "w1“.

Slowly increase command value "w1" from 0 V with positive polarity on the
command value module.
Slowly increase the command value further while observing the cylinder
velocity.
Activate the call-up "inversion" by means of switch "S1“ and change the
direction of movement of the cylinder.
With positive values the cylinder must extend.
Note for trainers:

This project focuses exclusively on the adjustment and activation of command
values. Further functions will be dealt with in the subsequent projects.
The position of elements is shown on page 5 of data sheet RE 29902.
It is important to understand that a command value and inversion must be
activated with a digital signal.
An LED indicates, which function is active.
This digital signal can be provided by a switch, relay or PLC output. The
measuring points for the command value are the test sockets at command
value module BPS 20.0, for the actual value the "actual value" test sockets
of operator module BPS 21.0. When no command value is active, the value
at test socket "w“ must be 0 V. Values up to +/- 1 V can be corrected with
potentiometer "Z“.
A voltage potential may build up at the differential input due to electrical interference.
In this case, the differential input must be short-circuited. In practice, open
differential inputs can cause so-called "ghost movements" or high-frequency
vibration.
The voltage at the differential input always adds to the called up command values.
After completion of practical work, switch the hydraulic pump on

the training system off! Open the proportional valve again in both
Caution directions +/- in order to unload the pressure in the working line
and in the cylinder. Set the pressure relief valves to minimum
pressure. No pressure gauge may indicate a pressure.

I. Which components are used for adjusting command values? 02
Command values are adjusted on the command value module with the help
of potentiometers.
II. How are the command values activated (called up)?

Command values must be activated (called up) with a digital 24 V signal.
III. How can the polarity be changed?

To change the polarity you must activate the signal inversion.
IV. Where can the current command value be measured?

The current command value can be measured at test socket "w“ against
"┴“.
V. Which value may the command value voltage take, when no command
value is activated, and where can the value be adjusted, if required?
When no command value is activated, the command value voltage must be
0 V; if required, it can be adjusted by means of "Z“.
In Project 02 basic knowledge is to be imparted with regard to the operation
of command value module BPS 20.0 in a practical setup.
The project order is an integral part of the general project "press moderniza-
tion" and is intended to make the trainees familiar with the signal flow and the
operating principle of the control.
The following knowledge is to be gained in the practical setup:
• Function of "digital call-ups“
• Command value adjustment
• Function of "inversion“
• Measuring point for command value
Project 03: Adjusting the command
value module 1 Bosch Rexroth AG I RE 00847/07.07
Project 03: Adjusting command value module SWMA1 with

4 command values
Project definition
03
For commissioning the machine control, which is still unknown to us, the latter
is to be tested for function first. During this, the trainees will be made familiar
with the signal flow and function of the command value module.
Fig. 03.01 Press control block with proportional valves
Project tasks
• Activation of various command values with digital signals
• Adjustment of command value voltages on the command value module
• Testing of polarities
• Measurement of the command value voltage at test socket "w“ against ┴ .
Project steps
• Informing: In which condition is the machine? What exactly is to be carried
out?
03

• Executing: Preparation of hydraulic and electrical circuit diagrams and

selection of the required drive elements and accessories with
short description.
Notes
03


S1
4 1 2 3 4
3
+ 24V 3
3 3 3
03
S3 S4 S5 S6
4 4 4 4
Inputs Outputs
Call-up 4 Comm. value w
Call-up 3 Reference ⊥ Comm./act. display
Inversion ± 10 V signal
Inv. Inputs Outputs ⊥ reference
Differential Control output Comm. Val. Act. value Display 2
input ±10 V ± 10 V (D) (F) ± 10 V ±10 V signal
± 10 V Reference ⊥ ⊥ ref. (E) (C) ⊥ ref. ⊥ reference
⊥ reference Supply Supply
4Q + 24 V (A) BPS 21.0 + 24 V
Supply BPS 6.1
0V
+ 24 V BPS 20.0
0V
+ 24V

1.0 1 Hydraulic cylinder ZY1.7 03

valve
1.4 1 Check valve DS2.1
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection

1
Allan key set
03
Note:
Safety notes
regulations must be observed before and during the execution 03
gauges to check that the system is depressurized

retracted with the help of a 4/3 proportional directional valve. With positive com-
mand values the cylinder must extend. The system pressure is to be limited.
Note for trainers:

On the basis of the data sheet the trainees are to make themselves familiar with
the function of digital call-ups and the adjustment of the command values and
apply this knowledge in the circuit diagram. Moreover, the position and function
of the control and indicator elements are to be taken from the data sheet.
The ramp potentiometers should all be set to the left-hand limit stop, because
the ramp function is dealt with in subsequent projects.
Prepare a circuit diagram and parts list in order to meet the requirements. 03
Mount the hydraulic components on the hardware training according to the
circuit diagram and connect them by means of hoses.
To connect pressure gauges with measuring line DZ 1.4 use pressure hoses
The electrical control must be set up so that with the help of the command
value module proportional valve 4WREE6 DW40E-D can be operated with
4 different command values.
Command value source BPS 5.2, command value module BPS 20.0, BPS
21.0, display BPS 6.1 must be permanently connected to 24 V.
The control voltage for switches, push-buttons, relays is switched with the
help of an "S1" switch.
It should be possible to call up the command values with the help of push-
buttons "S3-6“ .
The command value and actual value are to be measured and displayed.

3. Testing the command value module function

open.
Set the command values "w1-w4" to 2 V at the command value module.
The command values must be activated with 24 V of the relevant "call-up"
in order that the values can be read off. This is accomplished by operating
switch "S3-6“.
The measuring points are w, ┴ on command value module BPS 20.0 for the
command value, and F (+/-10V), C (┴) on BPS 21.0 for the actual value.
Observe the voltages for the command value and the actual value on com-
mand/actual value display BPS 6.1.
What happens, if two command values are activated simultaneously?
What are the polarities of the individual command values?

When no command value is activated, the command value must be 0 V.
If a value is displayed, potentiometer "Z" must be improperly trimmed.
In this case, adjust the command value to 0 V by means of "Z“.
03
Note for trainers:
This project focuses exclusively on the adjustment and activation of command
values. Further functions are dealt with in subsequent projects.
It is important to understand that command values are activated with a digital signal.
An LED signals, which value is active.
This digital signal can come from switches, push-buttons, relays, or PLC out-
puts.
If two command values are activated, "w1" has the lowest priority and "w4“
the highest priority.
"w1“, "w2“ have an internally positive connection, and "w3“, "w4“ a negative
connection.
The measuring points for the command value are test sockets “w“ "┴“ on the
command value module, those for the actual value test sockets "actual value"
on operator module BPS 20.0.
Switch the control voltage on.
Make the following settings on the command value module:
Command value "w1“ = 6 V, call up command value "w1" with push-button "S3“.
Command value "w2“ = 2.5 V, call up command value "w2" with push-button "S4“.
Command value "w3“ = -6 V, call up command value "w3" with push-button "S5“.
Command value "w4“ = -2.5 V, call up command value "w4" with push-button "S6“
Switch the hydraulic pump on and close the by-pass valve.
1. Move the cylinder with the help of push-buttons "S3-6“.
2. First operate push-button "S3“, then "S4“ and watch what happens.
The cylinder moves according to the pre-set command values when they are
activated. If two command values are activated simultaneously, the higher number
has always priority.


I. How many command values "w“ are provided on the command value
module?
4 different command values can be set on the command value module. 03
II. How can these command values be activated (called up) ?

The individual command values must be activated (called up) with a digital 24 V
signal.
III. How is signaled, which command value is active?

The active command value is indicated by an LED.
IV. What are the polarities of the individual command values?

The polarity of command values "w1“, "w2“ is positive, that of "w3“, "w4“ is
negative.
V. What are the priorities of command values "w1-4“?

Command value "w1“ has low, "w4“ high priority.
VI. How can the current command value be measured?

The current command value can be measured at test socket "w“, "┴“.
If no command value is activated, the command value voltage must be 0 V;
if required, it can be adjusted by means of "Z“ .
In Project 03 knowledge is to be imparted with regard to the operation of the
command value module in a practical setup.
The project order is an integral part of the general project "press modernization"
and is to help understand the signal sequence and the operating principle of
the control.
The practical setup is to impart knowledge of:
• Function of "digital call-ups“
• Command value adjustment
• Measuring point for command value
Project 04: Command values and ramps 1 Bosch Rexroth AG I RE 00847/07.07
Project 04: Adjusting command value module SWMA1 with

4 command values and ramps
Project definition
During commissioning of the machine control, the customer was dissatisfied
with the hard acceleration and deceleration. 04
This should be much smoother with the new technology.
Fig. 04.01 Control block with on/off and proportional valves
Project tasks
• Activation of different command values with digital signals
• Adjustment of command value voltages and ramps on the command value module
• Testing of ramp voltages at test socket "t“
• Measurement of command value voltage at test socket "w“
Project steps
• Informing: In which condition is the machine? What exactly is to be car-
ried out?

04

short description.
Notes
04


S1
1 2 3 4
3 4
+ 24V 3 3 3
3
S3 S4 S5 S6
4 4 4 4
04
Inputs Outputs
Command Measurands
value Command
Call-up 4 value w Command/actual
Call-up 3 Reference ⊥ value display
Connection panel
Call-up 1 Reference ⊥ Display 1
Inversion Input Outputs ± 10 V Signal
Inv. Command Actual value ⊥ Reference
Differential Control value (F) ± 10 V Display 2
Input output ± 10 V (D) (C) ⊥ ±10 V Signal
± 10 V ±10 V ⊥ Reference Reference ⊥ Reference
⊥ Reference Reference ⊥ (E) Supply
Ramp Supply Valve 0V
4Q 0V (B) BPS 21.0 + 24 V
Supply + 24 V (A) BPS 6.1
0V
+ 24 V BPS 20.0
0V
+ 24V

04

valve
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection

1
Allan key set
04
Note:
Safety notes
introduction of the present manual. 04

Note for trainers:

With the help of the data sheet the trainees are to make themselves familiar
with the function of ramps and their assignment to command values.
An important point is the table "ramp time" and the formula for converting the
measured voltage into a ramp time.
Moreover, the position and function of control and indicator elements is to be
taken from the data sheet.
To connect pressure gauges with measuring line DZ1.4 use pressure hoses
04
DZ25.1. Tighten the pressure gauge measuring lines at the relevant measur-
The electrical control must be set up so that with the help of the command
value module proportional valve 4WREE6 DW40E-D can be operated with
4 different command values.
21.0, and display BPS 6.1 must be permanently connected to 24 V.
A switch "S1“ is used to switch the control voltage for switches, push-but-
tons and relays.
It should be possible to call up the command values by means of push-but-
tons "S3-6“.
Command value and ramp voltage are to be measured and displayed.

3. Testing of the command value module function

open.
The command values must be activated with 24 V at the relevant "call-up"
in order that the values can be read off.
The ramps "t1-4“ are activated simultaneously with command values "w1-4“.
Set ramps "t1-5" to > 5 V (20 ms) on the command value module; this is the
minimum ramp time.
This is accomplished by operating push-buttons "S3-6“.
Ramp "t5“ is active, when no command value is activated.
Observe the command value voltage (test socket "w“, ┴) and the ramp volt-
age (measuring socket "t“, ┴) on command/actual value display BPS 6.1.
What happens, if two command values are activated simultaneously?

Which polarity have the individual command values?
If no command value is activated, the command value must be 0 V.
If a value is displayed, potentiometer "Z“ must be improperly trimmed.
In this case, adjust the command value to 0 V by means of "Z“.
Note for trainers:

04
This project deals exclusively with the adjustment of command value with the
associated ramps.
It is important to understand that command values and ramps are activated
simultaneously by digital signals.
An LED indicates, which values are active.
The digital signal can come from switches, push-buttons, relays or PLC out-
puts.
The measuring point for the command value and the ramp are the measuring
sockets on the command value module.
Switch the control voltage on.
The values can be measured at test socket "w“, "┴“.

Move the cylinder by operating push-buttons "S3-6“ and stop before the end
positions.
The cylinder moves according to the pre-set command values when these are
activated.
Because the ramp time of 20 ms is very short, the cylinder accelerates abruptly
and also comes abruptly to a standstill when the push-button is released.
To improve this behavior, the ramps are to be adjusted.
While the adjustments are being made, the by-pass valve can be opened.
Make the following settings on the command value module:
Command value "w1“ = 10 V, ramp "t1“ 1.0 V (100 ms); call up command
value "w1" by means of push-button "S3“.
Command value "w2“ = 0 V, ramp "t2“ 5.0 V (20 ms); call up command
value "w2" by means of push-button "S4“. 04
Command value "w3“ = -10 V, ramp "t3“ 0.5 V (200 ms); call up command
Command value "w4“ = -0 V, ramp "t4“ 0.05 V (2000 ms); call up command
Ramp "t5“ 0.2 V (500 ms); do not operate any push-button
After having made the adjustments, close the by-pass valve and traverse
the cylinder with the help of the push-buttons while observing the changed
behavior.
Operate "S3" for extending; when the cylinder is in motion, release "S3“.
When no command value is active, the cylinder is decelerated with ramp "t5“.
To retract the cylinder operate "S5“.
First operate "S3“; when the cylinder has set into motion, operate "S4" ad-
ditionally.
Because of the higher priority, "w2" is again active; since the command value
is 0 V, the cylinder is decelerated with ramp "t2“.
For retracting, operate "S5“; when the cylinder starts to move, release
"S5“.
If no command value is active, the cylinder is decelerated with ramp "t5“.
Operate "S3“ to extend the cylinder again.
First operate "S5“; when the cylinder has set into motion, operate "S6" ad-
ditionally.
Because of the higher priority, "w4" is active; since the command value is
0 V, the cylinder is decelerated with ramp "t4“.
Note:
Because ramp time "t4“ is relatively long with 2000 ms, the cylinder may already
be in its end position when the command value reaches 0 V. For this reason,
"S6“ should be operated already after a short cylinder stroke.

I. How many ramps can be set?

4 different command values and 5 ramps can be set on the command value
module.
04
II. How can the ramps be activated (called up)?
The individual command values with ramps must be activated (called up) with a
digital signal.
III. How are the ramps assigned to the command values?

The ramps are assigned to command values "w1, t1“, "w2, t2“, "w3, t3“, "w4,
t4“; "t5“ is not firmly assigned to a command value.
IV. Where can the ramp time be measured?

The current command value can be measured at test socket "w“.
V. What is the relationship between the measured voltage and the actual
ramp time?
The current ramp time can be measured at test socket "t“ .
VI. What is the relationship between the measured ramp voltage and the
actual ramp time?
The measured ramp voltage is inversely proportional to the actual ramp
time.
VII. Which ramp is active, when no command value is active?

When no command value is activated, "t5“ is active.
VIII. What do ramps influence?

The ramps have an influence on acceleration and deceleration characteris-
tics.
IX. Which effect has an excessively long ramp time?

Due to the ramp time, the cylinder moves on after the push-button was re-
leased.
X. Did the hard characteristics improve after the ramp time was adjusted?
It was possible to improve the characteristics. 04
In Project 04 the trainees are to become familiar with the operation of command
value module BPS 20.0 in a practical setup.
and is to help the trainees to understand the signal sequence and function of
the control.
• Function of the ramp
• Assignment of ramps to the command values
• Ramp adjustment
• Measuring point for the ramp adjustment
Project 05: Braking distance after proximity switch 1 Bosch Rexroth AG I RE 00847/07.07
Project 05: Adjusting a braking distance following a prox-

imity switch signal
Project definition
To get a better understanding of the braking characteristics of the press, the
press is to be decelerated from max. velocity to "0" with a braking distance of
50 mm.
How does the braking system behave with other command values? 05
The function and application of ramps is to be understood.
Fig. 05.01 Control block with on/off and proportional valves in the field
Project tasks
• Adjustment of a defined braking distance after a proximity switch
• Adjustment of command value voltages and ramps on the command value module
• Examination of influences on the braking distance
Project steps
out?

Where are the components and measuring points? 05

short description.
Notes
05

Electrical circuit diagram
05
Fig. 05.03 Electrical circuit diagram


S1
7 8
3 4
+ 24V
24 24
K1 K3
21 21
Inputs Outputs
Command value Measurands
Call-up 4 Command value w Command/
Call-up 3 Reference ⊥ actual display
05
Inversion ± 10 V Signal
Inv. S2 Inputs Outputs Actual ⊥ Reference
Differential input Control output Command value Display 2
3 4
± 10 V ±10 V value (F) ± 10 V ±10 V Signal
⊥ Reference Reference ⊥ ± 10 V (D) (C) ⊥ Reference ⊥ Reference
Ramp ⊥ Reference (E) Supply
4Q Supply Valve 0V
Supply 0V (B) + 24 V
0V + 24 V (A) BPS 21.0 BPS 6.1
+ 24 V BPS 20.0
0V
+ 24V

05
1.1 1 DW40E-D.
valve with load pressure valve
0.1- Pressure gauge with

3 DZ1.4
0.3 minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection

05
K1-K3 1 Control module BRS1.2
B1 1 Proximity switch, inductive DE2.2

1
Allan key set
Table 05.02 Parts list for electrical block circuit diagram Fig. 05.03 + Fig. 05.04
Notes
05
Note:
Safety notes
risks of injury and a safety risk during can arise operation of the 05
gauges to check that the system is depressurized

Note for trainers:

With the help of this data sheet the trainees are to make themselves familiar
with the function of ramps and their assignment to command values.
An important point is the ramp time table and the formula for converting the
measured voltage into a ramp time.
Moreover, the position and function of indicator elements is to be taken from
the data sheet.
To connect pressure gauges with measuring lines DZ1.4 use pressure hoses
DZ25.1. Tighten the pressure gauge measuring lines at the relevant measur-
05
The electrical control must be set up so that after a start signal the cylinder
extends, and after a proximity switch signal the cylinder is decelerated. After
a further signal the cylinder is to retract.
21.0, and display BPS 6.1 must be permanently connected to 24 V.
An "S1“ switch is used for switching the control voltage for switches, push-
buttons, and relays.
An "S2“ switch is used to connect BSP 20.0 output "+/- 10 V“ to BSP 21.0
input "D“, which is necessary for the command value adjustment in order
that proportional directional valve 4WREE6 DW40E-D is not operated while
adjustments are being made.
Push-button S3
→ Extending the cylinder with command value "w1“.
Proximity switch B1
→ Deceleration to standstill
Push-button S4
→ Retracting the cylinder with command value "w3“, even if B1 has not
switched.
The command value and ramp voltage are to be measured and displayed.

3. Pre-settings on the command value module

Hydraulic pressure is not yet required; the by-pass valve is to be opened.
Switch the control voltage on by operating "S1“.
"S2“ is open.
Set command values "w1" to 1.5 V, "w3" to -5 V on the command value
module.
Set ramps "t1“, "t3“, "t5“ to > 5 V (20 ms), which is the minimum ramp
time.
The command values and ramps must be activated with the relevant "call-up"
05
Ramps "t1-4“ are activated simultaneously with command values "w1-4“.
This is accomplished by operating push-button "S3“ or "S4“.
Ramp "t5“ is active, when no command value was activated.
Which ramp is active for decelerating the cylinder?
Note for trainers:

This project focuses on the adjustment of command values with the associ-
ated ramps.
It is important to understand that the velocity can be adjusted by means of
command values, and the braking distance by means of ramps.
Clarify, with which ramp the braking distance can be adjusted.
It is "t5“, because no command value is active.
The amount of the command value has an influence on the braking distance,
even if the ramp setting remains unchanged.
The ramp corresponds to the gradient of the command value signal.
This must be illustrated with the help of a diagram. (See Basic principles of
proportional valve technology, page 12)
The measuring points for the command value and the ramp are test sockets
"w“ and "t“ on the command value module.
The proximity switch has an operating distance of 8 mm; it must therefore be
placed very closely to the plexiglass guard.
In order that the cylinder cannot move while command value settings are being
made and reach the proximity switch faster than the values can be read off
and set, the command value signal to the valve is enabled by switch "S2“.
The ramp voltage for a braking distance of 50 mm is 0.12 V (+/-0.01 V).
05
Fig. 5.7 Definition of the position and adjustment of the proximity switch
4. Adjustment of the braking distance

The proximity switch is to be mounted at 250 mm.
Switch the hydraulic pump on.
Traverse the cylinder with the help of push-buttons "S3-4“ and operate "S2“
to enable the command value. The cylinder moves according to the pre-set
command values (1.5 V and -5 V). It must be verified whether the proximity
switch outputs a signal when the cylinder passes. Because the ramp time of
20 ms is very short, the cylinder is quickly accelerated and stops immediately
after having reached the proximity switch.
To simplify the determination of the switching point, the cylinder is to move
at low velocity "w1“ = 1.5 V.
The proximity switch must be adjusted so that the cylinder comes to rest
at 250 mm +/- 1mm. This is signal position "250 mm“, where the braking
distance starts.
Then the braking distance of 50 mm for max. velocity "w1“ = 5 V is to be
adjusted by means of ramp "t5“
To this end, extend the cylinder several times with "w1“ = 5 V, read off the
braking distance and adjust "t5“ until the braking distance is 50 mm.
Note the ramp voltage for a braking distance of 50 mm.
Thus, the initial setting is completed.
To examine the influence of the command value on the braking distance,
the braking distance is to be measured with different command values while
ramp "t5“ remains unchanged .
With the setting of "w1“ the command value must not be enabled to the valve
by "S2" , since otherwise, the cylinder extends faster than the command value
can be read off or adjusted.

When making adjustments, see to it that command value "w1“ is activated
with "S3“. This can also be recognized by LED "w1“.
After having adjusted the command value, enable the command value with
"S2“. The cylinder will then extend up to the proximity switch.
Enter the braking distance in the table.

on the training system off! Open the proportional valve again 05
Measured values Command value Braking distance Position

1.5 V 0 250
2.0 V 2 252
2.5 V 6 256
3.0 V 12 262
3.5 V 21 271
4.0 V 30 280 05
4.5 V 40 290
5.0 V 50 mm 300 mm
5.5 V 60 310
6.0 V 70 320
7.0 V 90 340
8.0 V 112 362
9.0 V 133 383
10.0 V 150 400 limit stop!
Note for trainers:

The established braking distances can differ from the given values. If several
training stands are used, different results and deviations are possible.
Causes:
Distance between the proximity switch and the cylinder pin
Different control behavior of the pumps
Reading tolerances, different temperatures, oil viscosities, loads
Position 250 mm at 1.5 V and the braking distance of 50 mm at 5 V must be
correct; otherwise the basic settings must have been made improperly.
These deviations also reflect the problem of open-loop controlled systems
and their multitude of influences on the position. In practice, it can often be
observed that each machine must be individually adjusted, although they are
all of the same design.
If a precise and reproducible position is required, closed-loop controlled systems
must be used, in which the cylinder position is measured and corrected.
This principle is increasingly applied in many modern systems.
One of the findings in this project is also to recognize the limits of simple,
open-loop controlled systems.

I. What is adjusted by means of the command value with reference to the
cylinder?
The command value is used to adjust the velocity.
II. What can be adjusted by means of the ramp with reference to the posi-
tion? 05
The ramp can be used to adjust a braking distance.
III. Remains the braking distance unchanged if the command value is in-
creased?
As the command value is increased, the braking distance becomes longer.
IV. Can difference in the braking distance have an adverse effect on the
function of the press?
The braking distance can have an adverse effect as a result of wide differ-
ences.
In Project 05 the trainees are to learn more about the operation of command
value module BPS 20.0 in a practical setup.
The project order is an integral part of the general project "press moderniza-
tion" and helps trainees to understand the signal sequence and function of the
control.
The following knowledge is to be imparted in the practical setup:
• Function of the ramp
• Assignment of ramps to the command values
• Ramp adjustment
• Measuring point for the ramp adjustment
Notes
05
Project 06: Pressure relationships 1 Bosch Rexroth AG I RE 00847/07.07
Project 06: Pressures of the proportional valve and their

influence on velocity and braking distance
Project definition
So far, the press has been operated without die. Now we are going to install
dies of different weights. It can be seen that the press operates at different
velocities although the settings remain unchanged.
How can we explain this "phenomenon“ to the surprised customer?
How does the braking distance behave at other velocities?
06
Fig. 06.01 Result of excessive speed and too long a braking distance.
Project tasks
• Adjustment of a defined braking distance after a proximity switch
• Adjustment of the command value voltages and ramps on the command value
module
• Examination of ∆p influences on the velocity and braking distance
Project steps
out?

(hydraulically and electrically)? 06
short description.
Notes
06

06


S1
7 8
3 4
+ 24V
24 24
K1 K3
21 21
Inputs Outputs
Inv. S2 Inputs Outputs Actual ⊥ Reference
06
3 4
4Q Supply Valve 0V
0V + 24 V (A) BPS 21.0 BPS 6.1
+ 24 V BPS 20.0
0V
+ 24V

1.1 1
valve with load pressure DW40E-D. 06
valve
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection

06

1
Allan key set
Table 06.02 Parts list for electrical block circuit diagram Fig. 06.03 + Fig. 06.04
Notes
06
Note:
Safety notes
Before starting work on the training stand, check that the elec- 06

retracted with the help of a 4/3 proportional directional valve.
The annulus side of the cylinder is to be pre-loaded by means of a pressure
relief valve for the simulation of a load.
The pressure relief valve is to be by-passed for retracting.
With positive command values the cylinder must extend.
The system pressure is to be limited.
The electrical control must be set up so that the cylinder starts to extend after
a start signal and decelerates after a proximity switch signal. After a further
signal, the cylinder is to retract.
21.0, display BPS 6.1 are permanently connected to 24 V.
An "S1“ switch is used to switch the control voltage for switches, push-but-
tons and relays.
An "S2“ switch is used to switch BSP 20.0 output "+/- 10 V“ to BSP 21.0
input "D“; this is required for command value adjustments in order that
proportional directional valve 4WREE6 DW40E-D is not operated while 06
adjustments are being made.
The command value and the ramp voltage are to be measured and dis-
played.
Push-button S3
→ Extending cylinder with command value "w1“.
Proximity switch B1
→ Deceleration to standstill
Push-button S4
→ Retracting cylinder with command value "w3“, even if B1 did not operate.
played.

3. Pre-setting the command value module

reason, the by-pass valve is open.
"S2“ is open.
Set command values "w1“ to 3 V, "w3“ to 5 V on the command value mod-
ule.
Set ramps "t1, 3, 5“ to 5 V (20 ms), which is the minimum ramp time.
The command values and ramps must be activated by the relevant "call-up"
Ramps "t1-4“ are activated simultaneously with command values "w1-4“.
This is accomplished by actuating push-buttons "S3-4“.
Ramp "t5“ is active when no command value is activated.
Which ramp is active for decelerating the cylinder?
Note for trainers:
In this project we deal with the simulation of different loads by pressurizing

the annulus cylinder chamber. This also changes the pressure in the cylin-
der piston chamber. The ∆p is changed while the system pressure remains
unchanged. Thus, the cylinder velocity varies although the command value
remains unchanged.
It is important to understand that the ∆p has an influence on the velocity.
This also has an influence on the braking distance, with unchanged command
value and ramp settings.
A diagram is to illustrate this phenomenon. (See Basic principles of proportional
valve technology, page 12)
06
The measuring points for the command value and the ramp are the test sockets
on the command value module.
The proximity switch has an operating distance of 8 mm; it must therefore be
located very closely to the plexiglass guard.
A further possibility is to vary the ∆p in order to change the system pressure.
Fig. 06.07 Definition of the position and setting of the proximity switch
4. Establishment of the velocity at different load pressures

Set the system pressure relief valve to 50 bar.
The proximity switch is not yet mounted.
Operate "S2“ for the command value enable and traverse the cylinder by
operating push-buttons "S3-4“.
While making command value settings, switch the command value enable
"S2" off. 06
After having made the settings, switch command value enable "S2" on again,
and the cylinder will extend to its limit stop.
To examine the influence of the ∆p on the velocity, extend the cylinder with
unchanged system pressure (50 bar), command value (3 V) and ramp (5 V)
at different load pressures from end position to end position.
The load pressure is the pressure in the cylinder piston chamber.
The load pressure is set by means of the load pressure valve and can only
be read off while the cylinder is extending.
After completion of practical work, switch the hydraulic pump on

the training system off! Open the proportional valve once again
Caution in both directions +/- in order to depressurize the working
line and the cylinder. Set the pressure relief valves to minimum
Measured values
Measure the time from start to stop using a stopwatch.
Load pressure Dp Time Velocity

10 bar 40 bar 2.6 s 154mm/s
15 bar 35 2.8 143
20 30 3.1 129
25 25 3.3 121 06
30 20 3.8 105
35 15 4.3 93
40 10 5.6 71
45 5 7.4 54
50 0 0
Diagram 06.01 Dp/velocity

Mount the proximity switch at 250 mm.

Operate "S2“ to grant the command value enable and traverse the cylinder
by operating push-buttons "S3-4“.
Verify whether the proximity switch outputs a signal when the cylinder
passes.
Because the ramp times "t1“ and "t5“ of 20 ms are very short, the cylinder
will quickly accelerate and come abruptly to a halt after having reached the
proximity switch.
The proximity switch must be adjusted so that the cylinder stops at 250 mm
+/- 1mm.
06

Pre-setting:
Command value "w1“ = 3 V.
10 bar load pressure in the cylinder piston chamber.
The load pressure can only be read off while the cylinder is extending.
Ramp "t5“ determines the braking distance of 30 mm at a load pressure of
10 bar.
To examine the influence of the ∆p on the braking distance, the braking

distance is measured at various load pressures, while the system pressure
(50 bar), command value "w1“ = 3 V and ramp "t5“ remain unchanged.
Enter the braking distance at different load pressures in the table.

The velocity values are taken from table 06.01.
From position 250 mm on, the command value is reduced to 0 V with ramp
"t5“.
Load pressure Dp Velocity Braking distance Position

10 bar 40 bar 154 mm/s 30 mm 280 mm
15 bar 35 bar 143 mm/s 28 mm 278 mm
20 bar 30 bar 129 mm/s 26 mm 276 mm
25 bar 25 bar 121 mm/s 23 mm 273 mm
30 bar 20 bar 105 mm/s 20 mm 270 mm
35 bar 15 bar 93 mm/s 15 mm 265 mm
40 bar 10 bar 71 mm/s 11 mm 261 mm
45 bar 5 bar 54 mm/s 4 mm 254 mm
50 bar 0 bar 0 mm/s - -


I. How does the cylinder velocity behave, when the ∆p is reduced?
When the ∆p is reduced, the cylinder velocity slows down.
II. Which influence does this have on the braking distance?

As the ∆p is reduced, the braking distance becomes shorter.
III. Can the difference in the ∆p and the braking distance have an adverse
effect on the function of the press?
06
The position depends on the ∆p, if the other settings remain unchanged; this
has an adverse effect, because the positions are different.
In Project 06 knowledge is to be imparted with regard to the pressure situa-
tion of proportional valves and their influence on the system characteristics in
a practical setup.
and helps to understand the pressure relationships of proportional valves.

• Pressure differential ∆p
• Flow in dependence upon ∆p and command value
• Influence on the braking distance
Notes
06
Project 07: 4-quadrant ramps 1 Bosch Rexroth AG I RE 00847/07.07
Project 07: Adjusting a motion sequence with 4-quadrant

ramps
Project definition
Optimum settings is to be found for operating the press.
To this end, the motion sequence of the press is to be configured with rapid
speed, creep speed and return. After a proximity switch B1 the press is to be
decelerated to creep speed.
The ramps are to be selected in the 4Q mode, that is, one ramp each for accel-
eration for extending, deceleration for extending, and acceleration for retracting,
deceleration for retracting.
07
Fig. 07.01 Press
Project tasks
• Adjustment of a motion sequence
• Adjustment of the command value voltages and 4Q ramps on the command
value module
Project steps
out?


07
short description.
Notes
07

07


S1
7 8 9 10
3 4
+ 24V
3 34 34 34
S2 K1 K2 K3
4 31 31 31
Inputs Outputs
Inv. Inputs Outputs Actual ⊥ Reference
4Q Supply Valve 0V
07
0V + 24 V (A) BPS 21.0 BPS 6.1
+ 24 V
BPS 20.0
0V
+ 24V


valve
07
1.4 1 Throttle check valve DZ 2.2
Pressure gauge with

0.1-0.3 3 Dz1.9
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection

07

1
Allan key set
Notes
07
Note:
Safety notes
system, including danger to life.
Warning
i.e. that the system is switched off. Use the system pressure 07
Caution

retracted with the help of a 4/3 proportional directional valve. The annulus
cylinder side is to be pre-loaded by means of a pressure relief valve for the
simulation of a load.
This pressure relief valve is to be by-passed for retracting.
With positive command values the cylinder must extend. The system pressure
is to be limited.
For the connection of pressure gauges with measuring lines ADZ1.4 use
pressure hoses DZ25.1. Tighten the pressure gauge measuring lines at the
relevant measuring point of the pressure hose hand-tight.
The electrical control must be set up so that the cylinder starts to extend with
a start signal and decelerates after a proximity switch signal. After a further
signal, the cylinder is to retract.
21.0, and display BPS 6.1 are permanently connected to 24 V.
An "S1“ switch is used to switch the control voltage for switches, push-but-
tons and relays.
With the help of an "S2“ switch, 4Q operation is to be switched on.
With push-button S3
After proximity switch B1
→ Decelerating 07
With push-button S4
→ Retracting the cylinder with command value "w3“, even if B1 has not
switched.
played.


reason, the by-pass valve is opened.
Set the following command values on the command value module:
"w1“ to 10 V, t1 = 0.5 V
"w2“ to 10 V, t2 = 0.5 V
"w3“ to -10 V, t3 = 0.5 V
Ramps "t1-5“ to 0.5 V = 200 ms.
Ramps "t1-4“ are activated simultaneously with command values "w1-4“,
when 4Q is switched off.
This is accomplished by operating push-buttons "S3-4“ and assigning "B1“.
Call-up "w4“, "t4“ is only briefly connected to 24 V for pre-setting purposes.
Ramp "t5“ is active, when no command value is active.
Which ramp is when active in 4Q operation?
Observe the voltages on the command/actual value display BPS 6.1.
Note for trainers:

This project deals with the adjustment of the motion sequence by means of
4-quadrant ramps. Of particular importance is the assignment of ramps to the
relevant changes in velocity (acceleration).
"t1“ accelerating - extending
"t2“ decelerating - extending
"t3“ accelerating - retracting
"t4“ decelerating - retracting
Use the diagram (see Basic principles of proportional valve technology, page
12) for the representation.
07
4. Adjustment of creep speed

The proximity switch is to be mounted at 200 mm.
Verify whether the proximity issues a signal when the cylinder passes.
The load pressure is 15 bar in the cylinder piston chamber.
Traverse the cylinder by operating push-buttons "S3-4“.

Reduce creep speed "w2" by 1 V after each cycle.
Observe the system pressure during the cylinder movement and note the
value.
At which command value becomes the cylinder remarkably more slowly?
Reduce command values "w2“ progressively further down to 1.5 V.
Command value "w2“ is adjusted when the cylinder is in its extended end posi-
tion.
LED "w2“ signals whether the command value is active.

on the training system off! Open the proportional valve again in
both directions +/- in order to depressurize the working lines
07
Caution
and the cylinder. Set the pressure relief valves to minimum pres-
sure. No pressure gauge may indicate a pressure.
Measured values
Read the system pressure off during rapid and creep speed with different com-
mand values "w2“.
Command System pressure System pressure

value "w2“ Rapid speed Creep speed
10 V 25 bar 25 bar
9V 25 bar 25 bar
8V 25 bar 27 bar
7V 25 bar 29 bar
6V 25 bar 32 bar
5V 25 bar 34 bar
07
4V 25 bar 43 bar
3.5 V 25 bar 46 bar slower
3.0 V 25 bar 48 bar
2.5 V 25 bar 50 bar
2.0 V 25 bar 50 bar
1.5 V 25 bar 50 bar
Note for trainers:

The cylinder velocity is only significantly reduced with command values below
4.0 V, because before, the cylinder velocity is determined by the displacement
of the pump. Only when the proportional valve throttles the flow to a value, at
which the maximum system pressure is reached and the pressure controller
reduces the pump output, becomes the cylinder slower. Here, the off-stroke
behavior of the pump is also of significance, for the pressure controller starts
to reduce the pump output even before 50 bar is reached.
Characteristic curves (measured at n=1450 min-1, v=41 mm2/s and q = 50 °C)

PV7/10-14

The cylinder is to accelerate swiftly and decelerate smoothly.
Rapid speed for extending "w1“ = 10 V
Accelerating "t1“ = 200 ms
Creep speed for extending "w2“ = 1.5 V
Decelerating "t2“ = 1000 ms
Rapid speed for retracting "w3“ = 10 V
Accelerating "t3“ = 100 ms
Decelerating "t4“ = 5V
Traverse the cylinder using "S3-4“ and observe it.

Operate switch "S2“ to activate the 4Q ramps. 07
Also other settings may be tested in this project.

I. Why becomes creep speed only effective below a relatively small command
value?
Less oil flows to the cylinder only, when the max. system pressure has been
reached and the pump starts to come off stroke. This takes place only with
small command values due the relatively small displacement of Q = 8 l/min.
II. How are the ramps assigned in 4Q operation?

In 4Q operation, the ramps are assigned to the 4 possible changes in the move-
ment.
III. Which benefit offers 4Q operation ?

In 4Q operation acceleration and deceleration for retracting and extending
can be optimally adjusted separately.
In Project 07 the transition from rapid speed to creep speed is adjusted, and
the function of 4-quadrant ramps is applied in a practical setup.
The project part is an integral part of the general project "press modernization"
and helps to understand the function of 4-quadrant ramps.

• Application of 4-quadrant ramps
• Adjustment of a motion sequence
07
Notes
07
Project 08: Sequence with 2 proximity switches 1 Bosch Rexroth AG I RE 00847/07.07
Project 08: Adjusting a sequence with 2 proximity switches
Project definition
So far, the cylinder has always been moved to its end position; now, a certain
halt position is to be approached. For the production, it is interesting, how exactly
a position can be approached and which effect changes in the load have.
The motion sequence of the press is to be adjusted with rapid speed, creep
speed and a defined halt position. The press is to be decelerated to creep
speed with the help of proximity switch B1. A proximity switch B2 is to be
used to decelerate the press to a defined position. The ramps are selected in
4Q operation, i.e. one ramp each for "accelerating - extending", "decelerating
- extending" and "accelerating - retracting", "decelerating - retracting“.
08
Fig. 08.01 Press die
Project tasks
• Adjustment of a motion sequence and a defined position
• Adjustment of command value voltages and 4Q-ramps on the command value
module
Project steps
out?


short description.
08
Notes
08

08


S1
7 8 9 10
3 4
+ 24V
3 34 34 34
S2 K1 K2 K3
4 31 31 31
22
K4 Inputs Outputs
21 Command value Measurands
4Q Supply Valve 0V
0V + 24 V (A) BPS 21.0 BPS 6.1
+ 24 V
BPS 20.0
08
0V
+ 24V


valve
08
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection
B1-B2 1 Proximity switch, inductive DE2.2

08

1
Allan key set
Notes
08
Note:
Safety notes
Hydraulic systems can store residual energy also after having 08

The annulus cylinder side is to be pre-loaded by means of pressure relief valve
for the simulation of a load.
is to be limited.
Use pressure hoses DZ25.1 for the connection of pressure gauges with
measuring line DZ1.4. Tighten the pressure gauge measuring lines at the
relevant measuring point of the pressure hose hand-tight.
The electrical control must be set up so that with a start signal the cylinder
extends, and after a proximity switch signal the cylinder is decelerated to creep
speed.
The cylinder is then to be stopped with the help of a second proximity switch.
After a further signal, the cylinder is to retract.
21.0 and display BPS 6.1 are to be permanently connected to 24 V.
An "S1" switch is used to switch the control voltage for switches, push-but-
tons and relays.
An "S2“ switch is to be used to switch on 4Q operation.
Use push-button S3
→ to extend the cylinder with command value "w1“
After proximity switch B1 08
→ the cylinder is to decelerate to creep speed "w2“
After proximity switch B2
→ deceleration to standstill, no command value, no 4Q operation
Use push-button S4
→ to retract the cylinder with comand value "w3“
The command value and the ramp voltage are to be measured and displayed.


reason, the by-pass valve is opened.
"w1“ to 5 V
"w2“ to 1.5 V
"w3“ to -5 V
Ramps "t1-5“ to 0.5 V (200 ms).
in order that the values can be read off and adjusted.
Ramps "t1-4“ are simultaneously activated with command values "w1-4“,
when 4Q is switched off.
This is accomplished by operating push-buttons "S3-4“ and assigning "B1“.
Call-up "w4“, "t4“ is to be connected only briefly to 24 V for the purpose of
presetting.
Ramp "t5“ is active, when no command value is activated.
Which ramp is when active in 4Q operation?
Read off the voltages for command values and ramps from command/actual
value display BPS 6.1.
Note for trainers:

In this project we deal with the adjustment of the motion sequence by means
of 4-quadrant ramps and a defined halt position. This halt position is to be ap-
proached at a very low velocity; for this reason, ramp "t5“ can be very short.
With such a short ramp time, changes in the velocity have no strong effect on
the position.
An important point is the assignment of the ramps to the relevant changes in
the velocity (acceleration).
"t1“ accelerating - extending 08
"t2“ decelerating - extending
"t3“ accelerating - retracting
"t4“ decelerating - retracting
"t5“ decelerating to standstill

Proximity switch B1 is to be mounted at 300 mm.
Set the load pressure to 15 bar in the cylinder piston chamber.
Activate 4Q-ramps.
Traverse the cylinder by operating push-buttons "S3-4“.
Check whether the proximity switches issue a signal when the cylinder
passes.
Adjust decelerating to creep speed so that braking is performed softly with
a braking distance of 50 mm. 08
Adjust the halt position at 390 mm with proximity switch B2 and ramp "t5“.
Measure the halt position at different load pressures.
To check the repeatability, operate the cylinder 4 times per setting.

on the training system off! Open the proportional valve again in
Caution both directions +/- in order to depressurize the working lines
and the cylinder. Set the pressure relief valves to minimum
Measured values
To check the repeatability, traverse the cylinder 4 times with each setting.
Load pressure 1st position 2nd position 3rd position 4th position
15 bar 390 mm 390 mm 390 mm 390 mm
20 bar 390 mm 390 mm 390 mm 390 mm
25 bar 390 mm 390 mm 390 mm 390 mm
30 bar 390 mm 390 mm 390 mm 390 mm
35 bar 390 mm 390 mm 390 mm 390 mm
40 bar 390 mm 390 mm 390 mm 390 mm
45 bar 389 mm 389 mm 389 mm 389 mm 08
Read off the halt position every 30s at a system pressure of 50 bar, a load pressure of
45 bar, 15 bar and a command value of 0 V.
Position at Position at
Time
45 bar 15 bar
0s 390 mm 390 mm
30 s 390 mm 391 mm
60 s 390 mm 392 mm
90 s 390 mm 393 mm
120 s 390 mm 394 mm
150 s 390 mm 395 mm
180 s 390 mm 396 mm
210 s 390 mm 397 mm
240 s 391 mm 398 mm

Note for trainers:
Depending on the setting of "t5" the halt position may vary; the shorter "t5“, the
smaller are the deviations. The results can absolutely differ for each group.
If required, repeat the exercise with "t5“ = 50 ms for all groups. The deviation
will be < 1 mm.
At standstill, the cylinder will drift and slowly extend due to the valve leakage.
Also here, the ∆p is the decisive factor for the amount of leakage oil.
In practice, this means that a position cannot be maintained for a long period
of time.
Whenever exact positions must be maintained under all circumstances, closed-
loop control systems are required.
08

I. Which measures resulted in an increase in the repeatability of the end
position?
The repeatability is improved at low velocity and with a short ramp.
II. Is the halt position exactly adhered to in the long run?

The position can not be maintained for a long period of time, because the pro-
portional valve is subject to leakage.
In Project 08 the transition from rapid speed to creep speed and a defined halt
position are to be set.
and is to explain the application of 4-quadrant ramps.
• Training in the application of 4-quadrant ramps
• Adjsutment of a motion sequence and a defined position
Project 09: Adjustment of an automatic sequence with 3

proximity switches
Project definition
So far, we have worked with a provisional control during commissioning, because
not all of the components required for an automatic control were available.
Now, we are going set up an automatic control which will be ready for opera-
tion.
During commissioning, particular emphasis is to be put on safety.
The motion sequence of the press with rapid speed, creep speed and return is
to be adjusted according to the customer's requirements.
With the help of a proximity switch B1 the press is to be decelerated to creep
speed.
With the help of a proximity switch B2 the press is to be stopped at the end
position.
After a holding time, the return stroke is to be initiated.
With the help of a proximity switch B3 the press is to be stopped with a defined
braking distance for the retracted cylinder. 09
The ramps are selected for 4Q operation.
With the help of the command value source, the press is to be operated manu-
ally at reduced velocity.
Fig. 09.01 Commissioning a power unit
Project tasks
• Safe commissioning
• Adjustment of a defined motion sequence and defined positions
• Adjustment of command value voltages and 4Q-ramps on the command value
module
Project steps
out?


short description.

09
Notes
09

09


S1
10 11 12 13
3 4
+ 24V
3 24 34 18
S2 K1 K2 KT1
4
21 31 15
32
K3 Inputs Outputs
31 Command value Measurands
Command value Differential input Control output Command value Display 2
provision ± 10 V ±10 V value (F) ± 10 V ±10 V Signal
Inputs Outputs Ramp ⊥ Reference (E) Supply
Supply Command 4Q Supply Valve 0V
0V value Supply 0V (B) + 24 V
24 V ±10 V Signal 0V + 24 V (A) BPS 21.0 BPS 6.1
⊥ Reference + 24 V
BPS 20.0
BPS 5.2
0V 09
+ 24V
Fig. 09.05 Command value source/command value module/connection panel/command/actual value display

valve
09
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection
B1-B3 3 Proximity switch, inductive DE2.2

09
1
Allan key set
KT 1 Time relay BRS2.1
Notes
09
Note:
Safety notes
must be discharged without any risk, e.g. by opening by-pass 09

The annulus cylinder side should be pre-loaded with the help of a pressure relief
valve for the simulation of a load.
is to be limited.
The electrical control must be set up so that with a start signal the cylinder
extends. After a first proximity switch the cylinder is to be decelerated to
creep speed. After a second proximity switch, the cylinder is to come to a
halt at a defined position.
The holding time is to be adjustable by means of a time relay.
When the holding time has elapsed, the return stroke is to be initiated.
A third proximity switch is used to decelerate the cylinder in the retracted
position.
21.0, display BPS 6.1 are to be permanently connected to 24 V.
An "S1“ switch is to be used for switching the control voltage for switches,
push-buttons, relays.
An "S2“ switch is to be used for switching on 4Q operation.
It should only be possible to start the cycle when the cylinder is retracted;
this is to be monitored by proximity switch B3.
Push-buttons S3+B3
09
Proximity switch B1
→ Decelerating to creep speed "w2“
Proximity switch B2
→ Decelerating the cylinder to standstill, 4Q OFF, start of holding time;
when the holding time has elapsed, retracting the cylinder with command
value "w3“.
Proximity switch B3
→ Decelerating to standstill; 4Q operation remains active
Manual operation should be possible with the help of command value source
BPS 5.2 at the differential input of the command value module. The max. ve-
locity should be limited in manual operation, even if higher values are selected
on the command value source.
The command value voltage and ramp voltage should be measured and
displayed.


Switch the control voltage on. Hydraulic pressure is not yet required; for
this reason, the by-pass valve is opened. Since the new control is not yet
known, particular attention should be paid to safety. It is dangerous, if the
press operates at excessive velocity due to an incorrect switching opera-
tion. For this reason, all command values should be set to 0 V. Should an
incorrect command value be activated in the event of a fault, no movement
can be initiated. The ramps are to be set to 200 ms. Long ramp times are
more dangerous, because after a stop signal the proportional valves closes
only very slowly. The cylinder then continues to move during this time. The
value from the differential input can be limited with the help of potentiometer
"G“.

"w1“ to 0 V
"w2“ to 0 V
"w3“ to 0 V
"G“ to 2.0 V with 10 V at the differential input 09
Ramps "t1-5“ to 0.5 V (200 ms).
Ramps "t1-4“ are simultaneously activated with command values "w1-4“,
when 4Q is switched off. This is accomplished with the operation of push-
button "S3“ and activation of "B1-3“. Call-up 4 can only be connected to
24V for adjustment purposes.
Ramp "t5“ is active, when no command value is activated
Which ramp is when active?
Read off the voltages from command/actual value display BPS 6.1.
Note for trainers:

In this project, knowledge is to be applied which was gained in the preceding
projects.
Also safety during commissioning of new controls is to be discussed.
For example, the activation of an incorrect command value should not result
in an uncontrolled movement.
If the command values are set to 0 V, the cylinders stops and nothing will
happen.
If the command value is set to, e.g. 10 V, the cylinder moves at max. velocity.
With long ramp times, the proportional valve has long reaction times.
Consequently, it is possible that the cylinder moves on after the command
value was switched off or that the position of a proximity switch is passed to
far. This can cause damage to the machine.
In manual operation, e.g. during setup, a certain velocity must not be exceeded
for safety reasons. This can be adjusted by means of "G“ on the command
value module. Thus, only 2.0 V may be applied to the output, even with 10 V
at the differential input. In practice, this means that the operator has no chance
to move the system faster in manual operation.
In manual operation, the control voltage for the relays must be switched off
by means of "S1“.
09
4. Adjustment of velocities and the halt position

Verify whether the proximity switches issue a signal when the cylinder
passes.
Switch the hydraulic pump on, close the by-pass valve.
Set the load pressure to 15 bar in the cylinder piston chamber.
Specification:
Starting position 50 mm
Rapid speed time 1s
Deceleration starting at 300 mm
Creep speed time 3s
Halt position 390 mm
Holding time 3s
Return time 2s
Halt/starting position 50 mm
09
Diagram 09.01 travel/time
Execution:
Traverse the cylinder manually to proximity switch B3 with the help of the com-
mand value source. Start the sequence with S3.
Adjust rapid speed, "w1“, "t1“.
Adjust creep speed, "w2“, "t2“ braking distance 40 mm.
Set halt position at 390 mm, B2, "t5“.
Adjust holding time KT1.
Adjust return stroke velocity, "w3“, "t3“.
Set stop position to 50mm, B3, "t4“.
Note for trainers:

The cylinder must first be moved to the starting position with the help of the
command value source, because without a B3 signal, starting is impossible. The
command value source must then be switched back to "0“, because otherwise,
the cylinder would move on with the value of the command value source.
Position 50 mm must be set so that the cylinder operates the proximity switch.
The signal forms the start condition.
Position 390 mm is to be set with a short "t5" ramp time.
Documentation:
Command values :
W1: 5 V
W2: 1.5 V
W3: -5 V
G: +/- 2 V
Ramps :
T1: 0.5 V 09
T2: 0.15 V
T3: 0.5 V
T4: 0.18 V
T5: 3.0 V
Pressures :
Rapid/creep speed
System pressure Extending: 35/50 bar Retracting: 47 bar
Piston side Extending: 15/17 bar Retracting: 20 bar
Annulus side Extending: 22/27 bar Retracting: 40 bar
Proximity switch position:

B1: 300 mm
B2: 390 mm
B3: 50 mm


I. Which measures were taken to improve safety during commissioning?
Command values set to 0 V means more safety during commissioning, since
no movement can take place.
II. How have long ramp times to be assessed?

With long ramp times, the machine continues to run, after the stop signal was
issued.
III. Which measure was provided for manual operation?

The velocity in manual operated was limited by means of "G“.
IV. What are the advantages of documentation?

09
In the event of a fault, the original settings are available.
In Project 09 an automatic sequence is to be set, in which a complete cycle is
performed upon a start signal and the initial position is approached again.
The project order is an integral part of the general project
"press modernization" and is intended to apply the know-
ledge gained so far.
In the practical setup, the following knowledge is to be deepened:
• Training in the application of 4-quadrant ramps
• Adjustment of a defined motion sequence
Notes
09
Project 10: Adjusting the system pressure with a potentiometer 1 Bosch Rexroth AG I RE 00847/10.08
Project 10: Adjusting the system pressure with the help of

an external potentiometer
Project definition
A baling press is to be operated with variable forces. The forces are to be ad-
justed by means of remote control with an electrical signal.
For commissioning the machine control which is still unknown to us, it should
first be adjusted carefully by hand. In this way, the behavior of the hydraulic
machine control can be understood.
Of particular interest is the relationship between command value and system
pressure.
10
Fig. 10.01 Example of proportional pressure valve (type DBEP6 is shown)
Project tasks
• Working out the function of the proportional valve
• Testing the valve function by measuring command value and pressure
• Determining the command value voltages for different pressures
Project steps
• Informing: In which condition is the machine? What in detail is to be
done?

How must the components be connected with each other
• Executing: Preparation of sketches of hydraulic and electrical cir-

cuit diagrams.
Set-up of the hydraulic control and the electrical circuit.
Determining the required values and their documentation.
• Checking: Which values can be set?
• Evaluating: How does the system behave? 10
Notes
Measuring
glass
Aggregate limit
10


Comm./actual
value display
Command value
Connection panel Diplay 1
provision
±10 V Signal
Inputs Outputs Inputs Outputs > Reference
Supply Comm. value Comm. value Actual value Diplay 2
0V ±10 V Signal ±10 V (D) (F) ±10 V ±10 V Signal
24 V > Reference > Refer. (E) (C) Refer. > > Reference
Supply Supply
BPS 5.2 0V (B) Valve 0V
+24 V (A) +24 V
BPS 21.0 BPS 6.1
T
P A (Y)
0V
+24 V
10
Fig. 10.04 Command value source/connection panel/command/actual value display

1.1 1 Proportional pressure valve DD18E
Pressure gauge with

0.1 1 DZ1.4
minimess line
Hydraulic hose with

1 DZ25.1 N-W
minimess connection

10
Table 10.02 Parts list for the electrics

VSK1
Measuring glass
DD18E
D DS2.1 VSK1
T
Connection block
DZ1.4
T
D Note:
DZ25.1 In connection elements
P
marked with D, the
10
components are directly
plugged into each other.
P
Fig. 10.05 Recommended component arrangement with component designations according to parts list Table 10.01 and
hydraulic circuit diagram Fig. 10.02
Note:
specific and adapted for use of the DS4 fastening grid.
Safety notes
risks of injury and a safety risk can arise during operation of the
must be discharged without any risk, e.g. by opening bypass or
operating directional valves.
10

The hydraulic circuit is set up so that the system pressure is limited by means
of a proportional pressure valve.
Set-up the circuit by following the steps below:
Mount the hydraulic components on the fastening grid according to the circuit
diagram and connect them using hoses.
To connect pressure gauges with measuring line DZ1.4, pressure hoses
DZ25.1 are used. Tighten the pressure gauge measuring lines at the relevant
measuring point of the pressure hose hand-tight.
Check the correct and tight connection of components to the pressure hoses
Requirements:
The electrical control must be set up so that proportional valve DBEE6
(DD18E) can be operated with command value source BPS 5.2. The com-
mand value is to be measured and displayed.
Tasks:
Set up the prepared circuit. Determine the measuring points.

of +/–10 V; never connect them to 24 V. This can cause damage
3. Testing the valve function

reason, the pump is not switch on and the bypass valve is open.
Generally, when taking voltage measurements, the signal (+/–10 V) must
always be measured against a reference (^). 10
The measuring points used on the BPS 21.0 are sockets D (+/–10 V) and
E (^) for the command value.
Run command values from 0 V to 10 V with positive polarity with the help of
command value source BPS 5.2.
Observe the voltage on command/actual value display BPS 6.1.
With a command value of 0 V, the lowest pressure possible is set.
First set the command value input to 0 V and turn the potentiometer to 0 V,
otherwise, an unwanted pressure is built up in the system.
Close the bypass valve.
Note the minimum pressure.
Slowly increase the command value from 0 V with positive polarity with the help
of command value source BPS 5.2 and observe the system pressure.

Caution
knowledge.
acteristics.
4. Adjusting the system pressure by providing a command value

With a command value of 0 V, the lowest pressure possible is set.
With a command value of 10 V, the highest pressure possible is set.
Adjust the command values according to the table by means of the command
value source BPS 5.2 and read off and enter the pressures
Note for trainers:

Function and structure of the DBEE6 proportional valve are described in detail
in the data sheet RE 29158 (pages 3 and 4).
Due to the existing pressure losses in the system (hose lines, couplings, valve),
the system pressure cannot be set to 0 bar. A system-specific minimum pres-
sure results that also depends on the flow.
The pressureless connection of A(Y) is important as otherwise, the control oil
cannot flow off. In this case, the maximum system pressure also results with
a command value of 0 V.
The maximum system pressure is determined by the pump's pressure controller.
10
Command value (in volt) Pressure (in bar)
0.5 10
1.0 12
1.5 15
2.0 17
2.5 20
3.0 22
3.5 25
4.0 27
4.5 30
5.0 32
5.5 35
6.0 37
6.5 40
7.0 43
7.5 46
8.0 48
8.5 50
9.0 50
9.5 50
10.0 50
Pressure
in bar
50
45
40
35
30
25
20
15
10
1 2 3 4 5 6 7 8 9 10 Command value
in V
Fig. 10.06 Command value/pressure characteristic curve
10
Note for trainers:

The pressure behaves almost linear in relation to the command value. The flow
in the pressure valve also has an influence because it is not constant.
From a value of approx. 8.5 V, the pressure does no longer increase as the
pump's pressure controller limits the maximally possible pressure.
After completion of practical work, set the command value at

Caution
the training system to 0 V. Switch off the pump. No pressure
gauge may indicate a pressure.

I. With a command value of 0 V, which pressure is available in the system?
With a command value of 0 V, the minimum pressure is available in the system.
II. Why can the pressure not be set to 0 bar with a command value of 0 V?
The pressure is determined by the pressure losses in the system and the flow
rate.
III. How has the system pressure changed in relation to the command value?
The system pressure has risen almost linearly.
IV. What limits the maximum system pressure?

The maximum system pressure is limited by the pump's pressure controller.
10
Project / trainer information
In Project 10, basic knowledge is to be imparted of the behavior of proportional
pressure valves in a practical set-up.
In the practical set-up, the following knowledge is to be imparted:
• Testing the valve function by measuring command value and pressure
• Knowledge of measuring points
• The amount of the command value determines the pressure.
Notes
10
Project 11: Moving the cylinder 1 Bosch Rexroth AG I RE 00847/10.08
Project 11 Moving a cylinder with to different pressures
Project definition
In a baling press, two different materials are compressed. The maximum pressing
power is 20 bar for material A and 40 bar for material B. The pressing power
must be complied with so that the materials get the desired characteristics.
It is thus necessary to operate the baling press with two preselectable pressures.
The powers are to be adjusted by means of remote control with an electrical
signal.
11
Fig. 11.01 Cylinder in tie rod design
Project tasks
• Preselection of a preset pressure
• Adjusting the command value voltages for different pressures
Project steps

done?

Where are the components and measuring points
located?

diagrams.
• Checking: Are the powers complied with?

11
Notes
Measuring
glass
11
Aggregate limit

11


7 8
+24 V
3 3
Command value
S1 S2
4 4 module
Inputs Outputs
Call-up 4 Comm. val. w Comm./actual
Call-up 3 Reference > value display
Call-up 1 Reference > Connection panel Diplay 1
Inversion ±10 V Signal
Inv. Control Inputs Outputs > Reference
Differential variable Comm. value Actual value Diplay 2
input ±10 V ±10 V (D) (F) ±10 V ±10 V Signal
±10 V Reference > > Refer. (E) (C) Refer. > > Reference
> Reference Supply Supply
4Q +24 V (A) +24 V
Supply
BPS 21.0 BPS 6.1
0V
+24 V
T
BPS 20.0
P A (Y)
0V
+24 V

11

1.1 1 Proportional pressure valve DD18E.
1.2 1 4/3 directional valve DW13E
Pressure gauge with

0.1-0.3 3 DZ1.4
minimess line
11
Hydraulic hose with
3 DZ25.1 N-W
minimess connection
K1-K3 1 Control module BRS 1.2
1 2 mm screw driver
Table 11.02 Parts list for electric block circuit diagram Fig. 11.03
11
Notes
VSK1
DZ1.4 ZY1.7 DZ1.4
Measuring glass
DW13E
VSK1
DS2.1 DD18E
T
Connection block
D
T
DZ1.4 D Note:
VSK1 In connection elements
P
marked with D, the

DZ25.1
P
11
hydraulic circuit diagram Fig. 11.02
Note:
Safety notes
11
A cylinder is to be extended/retracted and stopped by means of a directional
valve.
Requirements:
(DD18E) can be adjusted with command value source BPS 20.0.
Low pressure and high pressure are to be preselected by means of two
push-buttons. For this purpose, one command value is in each case called
up at the command value module.
The cylinder movement for retracting and extending is activated and stopped
by means of push-buttons.
The command value and the pressure are to be measured and displayed.
Tasks:

3. Pre-setting of the pressures 11

reason, the pump is not switch on and the bypass valve is open.
always be measured against a reference (^).
The measuring points used on the BPS 20.0 are sockets (+/–10 V) and ^
for the command value.
Using switch S1, activate command value 1 and at the command value module
BPS 20.0, set a voltage for 20 bar (value see table in Project 10).
Using switch S2, activate command value 2 and at the command value module
BPS 20.0, set a voltage for 40 bar (value see table in Project 10).
Read off the voltage from command/actual value display BPS 6.1.
With a command value of 0 V, the lowest pressure possible is set if no switch
has been actuated.

Caution
knowledge.
acteristics.
4. Moving the cylinder with 20 bar or 40 bar

Close the bypass valve.
Using S1, preselect a pressure of 20 bar and extend the cylinder.
Using S2, preselect a pressure of 40 bar and extend the cylinder.
Observe the cylinder's behavior and the pressure values
If necessary, adjust the command values for the necessary pressure.
Note the command values W1, W2:
20 bar → W1 = ..,. V
40 bar → W2 = ..,. V
Note for trainers:

The set pressure can only be reached in the cylinder's end position as the load
determines the system pressure.
After completion of practical work, set the command value at

the training system to 0 V. Switch off the pump. No pressure 11
Caution
gauge may indicate a pressure.

I. In which position of the cylinder has the preselected pressing power been
reached?
The preselected pressing power has been reached in the end position.
II. Why is no max. pressure possible during the cylinder movement?

The pressure is determined by the load of the cylinder.

In Project 11, basic knowledge is to be imparted of the behavior of proportional
pressure valves in a practical set-up.
• Presetting pressures
• Pressure build-up
Notes
11
Project 12: Automatic sequence with proportional valve 1 Bosch Rexroth AG I RE 00847/10.08
Project 12: Automatic sequence with proportional valve
Project definition
In a dewatering press, sludge is compressed for dewatering purposes. Sludge
may only be compressed slowly and with little force as otherwise, the material
becomes inhomogeneous and too much sludge is pressed through the dewater-
ing openings. Only if the material has been dewatered is it to be compressed
slowly with higher pressure.
The pressing power for dewatering is 15 bar, the stroke is to be carried out in
3 s. The maximum pressing power for the final compression is 45 bar and is to
slowly increase in 4 s.
The return stroke must only be performed if the pressing power has been dis-
charged so that impacts are avoided.
The movement is controlled by means of a directional on/off valve, the pressure
by means of a proportional valve.
12
Fig. 12.01 Section of a DBEE proportional directional valve with integrated electronics
Project tasks
• Developing a control for satisfying the requirements
• Adjusting the command value voltages for different pressures
• Adjustment of the ramps for pressure increase and discharge
Project steps

done?

Where are the components and measuring points located?

diagrams.
• Checking: Are the powers complied with?
Notes
12
Measuring
glass
12
Aggregate limit

12


S1
3 4 11 12 13
+24 V
34 34 34
Command value
K1 K2 K3
31 31 31 module
22 Inputs Outputs
K2 Comm. value Measurands
21 Call-up 4 Comm. val. w Comm./actual
Call-up 3 Reference > value display
Call-up 1 Reference > Connection panel Diplay 1
Inversion ±10 V Signal
Inv. Control Inputs Outputs > Reference
Command value Differential variable Comm. value Actual value Diplay 2
provision input ±10 V ±10 V (D) (F) ±10 V ±10 V Signal
±10 V Reference > > Refer. (E) (C) Refer. > > Reference
Inputs Outputs > Reference Supply Supply
Supply Comm. value Ramp 0V (B) Valve 0V
0V ±10 V Signal 4Q +24 V (A) +24 V
24 V > Reference Supply
BPS 21.0 BPS 6.1
0V
BPS 5.2 +24 V
BPS 20.0 G A B
a 0 b
a b
P T
0V
+24 V
12
Fig. 12.05 Command value source/command value module/connection panel/command/actual value display
1.1 1 Proportional pressure valve DD18E
1.2 1 4/3 directional valve DW13E
1.5 1 Throttle check valve DF2.2
12
1.6 1 Pressure switch DD6E.1
0.1 Pressure gauge with

2 DZ1.4
0.3 minimess line
Hydraulic hose with

3 DZ25.1 N-W
minimess connection
K1-K3 1 Control module BRS 1.2
B1 1 Proximity switch, inductive DE 2.2
KT 1 Time relay BRS 2.1
1 Stop watch, 2 mm screw driver
Table 12.02 Parts list for electric block circuit diagram Fig. 12.03 12
Notes
VSK1
ZY1.7
DZ1.4
DD6E.3 DF2.2
Measuring glass
DW13E
VSK1
DS2.1 DD18E
T
Connection block
D
T
DZ1.4 D Note:
VSK1 In connection elements
P
marked with D, the

DZ25.1
P
hydraulic circuit diagram Fig. 12.02 12
Note:
Safety notes

12
A cylinder is to be extended/retracted and stopped by means of a directional
valve. For the loading and for setting the extending time of 3 s, an outlet throttle
is installed on the annulus side of the cylinder.
Switch-over to the higher pressing power is only effect shortly before the end
position at 350 mm by means of a proximity switch.
The pressing time of 4 s is adjusted by means of a ramp.
Discharge and return stroke are initiated by a pressure switch signal at 45 bar.
The discharge time of 2 s is adjusted by means of a ramp.
The return stroke is activated in a delayed form by means of a time relay.
The delay time is to be adjusted so that the return stroke is only activated after
the pressure has been discharged.
Requirements:
(DD18E) can be adjusted with command value source BPS 20.0.
By means of a switch, the sequence can be interrupted at any time.
The working process is started by means of a push-button.
The extending time is set to 3 s by means of the outlet throttle.
Switch-over to the higher pressing power is only effect shortly before the
end position at 350 mm by means of a proximity switch. 12
The pressing time of 4 s is adjusted by means of a ramp.
Discharge and return stroke are initiated by a pressure switch signal at 45
bar.
The discharge time of 2 s is adjusted by means of a ramp.
The return stroke is activated in a delayed form by means of a time relay. The
delay time is to be adjusted so that the return stroke is only activated after
the pressure has been discharged
The return stroke is carried out with a lower pressure of 12 bar.
The command value and the pressure are to be measured and displayed
Tasks:

3. Adjustments
Switch the pump on and close the bypass valve.
Switch the control voltage on by operating S1.
Using push-button S2, activate command value 1 and at the command value
module BPS 20.0, set a voltage for 15 bar as command value W1 and a
ramp time of 1 s.
So that the cylinder does not extend, the outlet throttle is closed for the adjustment.
Adjust the outlet throttle for an extending time of 3 s.
The proximity switch is adjusted so that there is a signal at 350 mm.
The command value W2 is adjusted for 45 bar and the ramp time to 4 s.
The pressure switch will switch at 45 bar.
The command value W3 is adjusted for 12 bar and the ramp time to 2 s.
The time relay is adjusted so that the return stroke is only carried out if the
pressure has been discharged.
always be measured against a reference (^).
The measuring points used on the BPS 20.0 command value module are the
sockets W (+/–10 V) and ^ for the command value. 12
Read off the voltage from command/actual value display BPS 6.1.
With a command value of 0 V, the lowest pressure possible is set if no switch
has been actuated.

Caution
knowledge.
acteristics.
Note for trainers:

The pressure to be set can only be reached in the cylinder's load as the load
determines the system pressure.
After completion of practical work, switch the pump on the

training system off. Afterwards, actuate the directional valve
Caution once again for the pressure discharge. No pressure gauge may
indicate a pressure.

I. Why is no maximum pressure possible during the cylinder movement?
The pressure is determined by the load of the cylinder.

In Project 12, knowledge is to be imparted regarding the use of proportional
pressure valves with directional on/off valves in a practical set-up.
• Working out an automatic sequence
• Presetting pressures
• Pressure build-up and pressure discharge
• The ramp determines the pressure build-up or the discharge.
Notes
12
12
4/2 and 4/3 proportional directional RE 29061/11.12 1/22
Replaces: 05.12
valves, direct operated,
with electrical position feedback,
without/with integrated electronics (OBE)
Type 4WRE and 4WREE
Size 6 and 10
Component series 2X
Maximum operating pressure 315 bar
Maximum flow: 80 l/min (size 6)
180 l/min (size 10)
Table of contents Features

Contents Page – Direct operated proportional directional valve with electri-
Features1 cal position feedback and integrated electronics (OBE) with
type 4WREE
Ordering code 2
– Control of flow direction and size
Symbols3
– Operation by means of proportional solenoids with central
Function, section 4, 5
thread and detachable coil
Technical data 6, 7
– For subplate mounting: Porting pattern according to ISO 4401
Electrical connection, mating connectors 8, 9
– Spring-centered control spool
Block diagram of the integrated electronics (OBE) for
– Control electronics
type 4WREE 10
• Type 4WREE:
Characteristic curves 11 to 17 integrated electronics (OBE) with voltage or current input
Unit dimensions 18 to 22 (A1 and/or F1)
• Type 4WRE (4/3 version), separate order:
- digital and analog amplifier in Euro-card format
- analog amplifier in modular design
• Type 4WRE…A (4/2 version), separate order:
- analog amplifier in modular design
Information on available spare parts:

www.boschrexroth.com/spc
2/22 Bosch Rexroth AG Hydraulics 4WRE; 4WREE RE 29061/11.12
Ordering code
4WRE 2X G24 V *
Without integrated Further details in

electronics (OBE) = no code the plain text
With integrated Seal material
electronics (OBE) =E V = FKM seals 1)
Size 6 =6 Electronic interface
Size 10 = 10 A1 = Command value ±10 V
Control spool symbols F1 = Command value 4 to 20 mA
no code = Type 4WRE

Electrical connection
Type 4WRE:
K4 = Without mating connector,
= E with connector according
to DIN EN 175301-803
E1–
Mating connector (solenoid, position
transducer), separate order, see page 8
Type 4WREE:
= V K31 = Without mating connector,
V1– with connector according
to DIN EN 175201-804
Mating connector – separate order,
see page 9
= W
Supply voltage
W1–
G24 = Direct voltage 24 V
2X = 20 to 29
(20 to 29: unchanged installation and
connection dimensions)
Rated flow at valve pressure differential Δp = 10 bar
Size 6

04 = 4 l/min
08 = 8 l/min
= EA 16 = 16 l/min
32 = 32 l/min
Size 10
25 = 25 l/min
50 = 50 l/min
= WA
75 = 75 l/min
With symbol E1–, V1– and W1–:

P → A: qV max B → T: qV/2 1) Design SO660 with NBR seals at the valve connection surface
P → B: qV/2 A → T: qV max
Notice:
In the zero position, spools W and WA have a con-
nection from A to T and B to T with approx. 3 % of the
relevant nominal cross-section.
RE 29061/11.12 4WRE; 4WREE Hydraulics Bosch Rexroth AG 3/22
Symbols
Proportional directional valve without integrated electronics Proportional directional valve with integrated electronics
Type 4WRE… Type 4WREE…

Type 4WRE…A… Type 4WREE…A…

Function, section
Type 4WRE …-2X/…

The 4/2 and 4/3 proportional directional valves are designed Function:
as direct operated devices in plate design. Operation is effect- – With de-energized solenoids (7 and 8), central position
ed by proportional solenoids with central thread and detach- of the control spool (2) by compression springs (3 and 4)
able coil. The solenoids are controlled by external electronics. between spring plates (5 and 6)
Set-up: – Direct operation of the control spool (2) by controlling a pro-
The valve basically consists of: portional solenoid, e.g. solenoid "b" (8)
– Housing (1) with connection surface → Displacement of the control spool (2) to the left propor-
– Control spool (2) with compression springs (3 and 4) and tional to the electric input signal
spring plate (5 and 6) → Connection from P to A and B to T via orifice-type
– Solenoids (7 and 8) with central thread cross-sections with progressive flow characteristic
– Position transducer (9) – Switching off of the solenoid (8)
→ The compression spring (3) brings the control spool (2)
back into the central position
In the de-energized condition, the control spool (2) is held in
a mechanical central position by the return springs. With con-
trol spool symbol "V", this position does not correspond to the
Important note! hydraulic central position! When the electric valve control loop
The PG fitting (11) must not be opened. Mechanical ad- is closed, the control spool is positioned in the hydraulic cen-
justment of the adjustment nut located below is prohibit- tral position.
ed and damages the valve!

Valve with 2 spool positions: (Type 4WRE…A…)

to the
The function of this valve design basically corresponds
valve with three spool positions. The 2 spool position valves
are, however, only equipped with solenoid "a" (7). Instead of
the 2nd proportional solenoid, there is a plug screw (10).
Notice! Notice!
Due to the design principle, internal leakage is inherent to the The tank line must not be allowed to run empty. With corres-
valves, which may increase over the life cycle. ponding installation conditions, a pre-charge valve (pre-char-
ging pressure approx. 2bar) is to be installed.

Function, section
Type 4WREE …-2X/…

The 4/2 and 4/3 proportional directional valves are designed Function:
as direct operated devices in plate design. Operation is ef- – With de-energized solenoids (7 and 8), central position
fected by proportional solenoids with central thread and de- of the control spool (2) by compression springs (3 and 4)
tachable coil. The solenoids are controlled by the internal between spring plates (5 and 6)
electronics.
– Direct operation of the control spool (2) by controlling a pro-
Set-up: portional solenoid, e.g. solenoid "b" (8)
The valve basically consists of: → Displacement of the control spool (2) to the left propor-
– Housing (1) with connection surface input signal
tional to the electric

– Control spool (2) with compression springs (3 and 4) and → Connection from P to A and B to T via orifice-type cross-
spring plate (5 and 6) sections with progressive flow characteristic
– Solenoids (7 and 8) with central thread – Switching off of the solenoid (8)
– Position transducer (9) → The compression spring (3) brings the control spool (2)
– Integrated electronics (13) back into the central
position
– Electric zero point adjustment (12) accessible via Pg7 In the de-energized condition, the control spool (2) is held in
a mechanical central position by the return springs. With con-
trol symbol "V", this position does not correspond to the
spool
Important note! central
hydraulic position! When the electric valve control loop

The PG fitting (11) must not be opened. Mechanical ad-

is closed, the control spool is positioned in the hydraulic cen-
justment of the adjustment nut located below is prohibit- tral position.
ed and damages the valve!

Valve with 2 spool positions: (Type 4WREE…A…)

The function of this valve design basically corresponds to the
valve with three spool positions. The 2 spool position valves
are, however, only equipped with solenoid "a" (7). Instead of
the 2nd proportional solenoid, there is a plug screw (10).
Notice! Notice!
Due to the design principle, internal leakage is inherent to the The tank line must not be allowed to run empty. With cor-
valves, which may increase over the life cycle. responding installation conditions, a pre-charge valve (pre-
charging pressure approx. 2 bar) is to be installed.
outside these parameters please consult us!)

Technical data (For applications
general
Sizes Size 6 10
Weight – Type 4WRE kg 2.2 6.3
– Type 4WREE kg 2.4 6.5
Installation position Any, preferably horizontal
Ambient temperature range – Type 4WRE °C –20 to +70
– Type 4WREE °C –20 to +50
Storage temperature range °C –20 to +80
MTTFd values according to EN ISO 13849 Years 150 1) (for more information see data sheet 08012)
hydraulic (measured with HLP46, ϑOil = 40 °C ± 5 °C and p = 100 bar)

Maximum operating – Port A, B, P bar 315
pressure – Port T bar 210
Rated flow qV rated with Δp = 10 bar l/min 4, 8, 16, 32 25, 50, 75
Recommended maximum flow l/min 80 180
Hydraulic fluid See table below
Hydraulic fluid temperature range °C –20 to +80 (preferably +40 to +50)
Viscosity range mm2/s 20 to 380 (preferably 30 to 46)
Maximum admissible degree of contamination of the hydraulic fluid, Class 20/18/15 2)
cleanliness class according to ISO 4406 (c)
Hysteresis % ≤ 0.1
Range of inversion % ≤ 0.05
Response sensitivity % ≤ 0.05
Zero shift upon change of hydraulic %/10 K ≤ 0.15
fluid temperature and operating pressure %/100 bar ≤ 0.1
1) Withcontrol spool types E, E1, EA, W, W1, WA; in longitudinal control spool direction, there is sufficient positive overlap
without shock/vibration load; observe the installation orientation with regard to the main direction of acceleration.
2) The cleanliness classes specified for the components must be adhered to in hydraulic systems. Effective filtration prevents
faults and at the same time increases the service life of the components.
For the selection of the filters see www.boschrexroth.com/filter
Hydraulic fluid Classification Suitable sealing Standards

materials
Mineral oils and related hydrocarbons HL, HLP NBR, FKM DIN 51524
HFC (Fuchs HYDROTHERM 46M,
Flame-resistant – Containing water NBR ISO 12922
Petrofer Ultra Safe 620)
Important information on hydraulic fluids! – Flame-resistant – water-containing: Maximum pressure
differential per control edge 175 bar. Pressure pre-loading
– For more information and data on the use of other hydrau-
at the tank port > 20 % of the pressure differential; other-
lic fluids refer to data sheet 90220 or contact us!
wise, increased cavitation.
– There may be limitations regarding the technical valve
Life cycle as compared to operation with mineral oil HL,
data (temperature, pressure range, service life, mainte-
HLP 50 % to 100 %.
nance intervals, etc.)!
– The flash point of the process and operating medium used
must be 40 K higher than the maximum solenoid sur-
face temperature.
Technical data (For applications outside these parameters please consult us!)
electric
Size Size 6 10
Voltage type Direct voltage
Solenoid coil – Cold value at 20 °C Ω 2.65 4.55
resistance – Maximum hot value Ω 4.05 6.82
Duty cycle % 100
Maximum coil temperature 1) °C up to 150
Electrical connection – Type 4WRE With connector according to DIN EN 175301-803 and ISO 4400
see page 8 and 9 Mating connector according to DIN EN 175301-803 and ISO 4400 2)
– Type 4WREE With connector DIN EN 175201-804
Mating connector DIN EN 175201-804 2)
Protection class of the valve according to EN 60529 IP65 with mating connector mounted and locked
Control electronics
Type 4WRE 4/3 version
Amplifier in Digital VT-VRPD-2-2X/V0/0 according to RE 30126
euro-card format 2) Analog VT-VRPA2-1-1X/V0 VT-VRPA2-2-1X/V0
according to data sheet 30119 according to data sheet 30119
Module amplifier 2) Analog VT-MRPA2-1 VT-MRPA2-2
Type 4WRE…A… 4/2 version
Module amplifier 2) Analog VT-MRPA1-1 VT-MRPA1-2
Type 4WREE Integrated in the valve, see page 9
analog command value module VT- SWMA-1-1X/... according to data sheet 29902
analog command value module VT-SWMAK-1-1X/... according to data sheet 29903
analog command value card VT-SWKA-1-1X/... according to data sheet 30255
digital command value card VT-HACD -1-1X/... according to data sheet 30143
Supply voltage Nominal voltage VDC 24
lower limit value V 19.4
upper limit value V 35
Current consumption Imax A <2
of the amplifier Pulse current A 3
1) Dueto the temperatures occurring at the surfaces of the Notice: For information on the environmental simula-
solenoid coils, the European standards ISO 13732-1 and tion testing for the areas EMC (electromagnet-
EN ISO 4413 need to be adhered to! ic compatibility), climate and mechanical load
2) Separate order see data sheet 29061-U (declaration on envi-
ronmental compatibility).
Electrical connection, mating connectors (dimensions in mm)
Type 4WRE (without integrated electronics)
Connection to connector Connection to mating connector

to the amplifier to the amplifier

Mating connector CECC 75 301-803-A002FA-H3D08-G

according to DIN EN 175301-803 and ISO 4400

Solenoid a, color gray

separate order under the Material no. R901017010

Solenoid b, color black

1 Mounting screw M3
Tightening torque MA = 0.5 Nm + 0.1 Nm

Inductive position transducer
Coil connection Connection to plug-in connector
to the amplifier
Ground signal
to the amplifier
Ground supply

Signal
supply
Coil

Mating connector 4-pole Pg7-G4W1F
Connection cable:

Recommendation:

up to 50 m cable length type LiYCY 4 x 0.25 mm2

Connect shield to PE only on the supply side.

Electrical connection, mating connectors (dimensions in mm)

Type 4WREE (with integrated electronics (OBE)
Mating connector according to DIN EN 175201-804

separate order under the Material no. R900021267 (plastic version)
Angular design – separate order under the Material no. R900217845
Pin assignment see also block diagram page 10

Mating connector according to DIN EN 175201-804
separate order under the Material no. R900223890 (metal version)

Device connector allocation Contact Signal with A1 interface Signal with F1 interface
Supply voltage A 24 VDC (u(t) = 19.4 to 35 V); Imax = 2 A
B 0 V
Reference potential actual value C Reference contact F; Re > 50 kΩ Reference contact F; Re < 10 Ω
Differential amplifier input D ±10 V command value; Re > 50 kΩ 4 to 20 mA command value; Re > 100 Ω
E Reference potential command value
Measuring output (actual value) F ±10 V actual value 4 to 20 mA actual value,
(limit load 5 mA) load resistance max. 300 Ω
PE Connected to cooling element and valve housing
Command value: Positive command value 0 to +10 V (or 12 to 20 mA) at D and reference potential at E result in flow
from P → A and B → T.
Negative command value 0 to –10 V (or 12 to 4 mA) at D and reference potential at E result in flow
from P → B and A → T.
For valves with 1 solenoid on side a (e. g. variant EA and WA), a positive command value 0 to +10 V
(or 4 to 20 mA) at D and reference potential at E result in flow from P → B and A → T.
Actual value: ctual value 0 to +10 V (or 12 to 20 mA) at F and reference potential at C result in flow from P → A and
A
B → T, actual value 0 to –10 V (or 4 to 12 mA) result in flow from P → B and A → T.
With valves with 1 solenoid, a positive actual value 0 to +10 V (or 4 to 20 mA) at F and reference potential
at C result in flow from P → B and A → T.
Connection cable: Recommendation: – up to 25 m cable length type LiYCY 7 x 0.75 mm2
– up to 50 m cable length type LiYCY 7 x 1.0 mm2
External diameter see sketch of mating connector
Connect shield to PE only on the supply side.
Integrated electronics (OBE) type 4WREE

Block diagram / pin assignment
Interface Integrated electronics (OBE) Valve
Differential

Command value amplifier

Reference Ramp
potential generator 2) Controller
Actual value
Actual value

Reference
potential
Undervoltage
detection
Locking
Supply Power supply unit

voltage 24 V Oscillator

GND
Demodulator
Protective earth-
ing conductor 1)

Position
Sensitivity Zero point 3) trans-
ducer
Notice: Electric signals taken out via control electronics (e.g. actual value) must not be used for switching off safety-
relevant machine functions!
1) Theprotective earthing conductor (PE) is connected to cooling ±10 V/4...20 mA actual position
element and valve housing! +24 V
2) Ramp can be set from 0 to 2.5 s from the outside, identical for 0V
Tup and Tdown
3) Zero point can be set from the outside
Reference actual position
±10 V/4...20 mA signal input
Symbol Reference input

Material no. Valve type

Serial valve no. to the
Internal manufac- manufacturing order
turing order no.
Year of construction, week of
construction + country code
Characteristic curves: Type 4WREE (measured with HLP46, ϑOil = 40 °C ± 5 °C) Size 6 and 10
Pressure signal characteristic curve (control spool V),

ps = 100 bar
Size 6

in % →

ΔpL
pS

←

UE
← in % →
UEN
Size 10

in % →

ΔpL
pS

←

UE
← in % →
UEN
Characteristic curves: Type 4WREE (measured with HLP46, ϑOil = 40 °C ± 5 °C) Size 6 and 10
Zero flow with central control spool position
Type 4WREE 6 V32 Type 4WREE 10 V75

Zero flow in l/min →
Zero flow in l/min →

Operating pressure in bar → Operating pressure in bar →
Characteristic curves: Type 4WREE (measured with HLP46, ϑOil = 40 °C ± 5 °C and p = 100 bar) Size 6
4 l/min rated flow with 10 bar valve pressure differential
1 Δp = 10 bar constant
P→A/B→T
or 3 Δp = 30 bar constant

Flow in l/min →
P→B/A→T 4 Δp = 50 bar constant


Control spool V

Control spool E- and W

Command value in % →
P→A/B→T 2 Δp = 20 bar constant

Flow in l/min →

Control spool V



P→A/B→T

Flow in l/min →

Control spool V








Flow in l/min →

Maximum admissible flow
Notice:
Observe the performance limits on
page 15!

Δp = Valve pressure differential (inlet
pressure pP minus load pressure pL
minus return flow pressure pT)

Control spool V



Flow in l/min →



Control spool V


50 l/min rated flow with 10 bar valve pressure differential 1 Δp = 10 bar constant

Flow in l/min →


Control spool V

Command value in % → Maximum admissible flow
Notice:
Observe the performance limits on
P→A/B→T page 15!

or



Flow in l/min →

Δp = Valve pressure differential (inlet
pressure pP minus load pressure pL

minus return flow pressure pT)

Control spool V


Transition function with stepped electric input signals: Type 4WREE Size 6
(measured with HLP46, ϑOil = 40 °C ± 5 °C and ps = 10 bar)
4/3 valve version Signal change in %
Control spool E

Stroke in % →

Time in ms →
Frequency response characteristic curves: Type 4WREE

(measured with HLP46, ϑOil = 40 °C ± 5 °C, ps = 10 bar) Size 6
4/3 valve version
Control spool V

Amplitude ratio in dB →
Phase angle in ° →

Frequency in Hz →
Signal ±10 %
Signal ±25 %
Signal ±100 %
Transition function with stepped electric input signals: Type 4WREE Size 10
(measured with HLP46, ϑOil = 40 °C ± 5 °C and ps = 10 bar)
4/3 valve version Signal change in %
Control spool E

Stroke in % →

Time in ms →
Frequency response characteristic curves: Type 4WREE

(measured with HLP46, ϑOil = 40 °C ± 5 °C, ps = 10 bar) Size 10
4/3 valve version
Control spool V

Amplitude ratio in dB →
Phase angle in ° →

Frequency in Hz →
Signal ±10 %
Signal ±25 %
Signal ±100 %
Flow: Type 4WREE (measured with HLP46, ϑOil = 40 °C ± 5 °C) Size 6

Load function with maximum valve opening
Rated flow 4, 8, 16 and 32 l/min
Control spool V
Maximum admissi-

ble flow

Flow in l/min →

P→A/B→T
or
P→B/A→T

Valve pressure differential in bar →
Observe the maximum admissible flow of 80 l/min!
Flow: Type 4WREE (measured with HLP46, ϑOil = 40 °C ± 5 °C) Size 10

Load function with maximum valve opening
Rated flow 25, 50 and 75 l/min
Control spool V

Maximum admissi-
ble flow

P→A/B→T
Flow in l/min →
or
P→B/A→T

Valve pressure differential in bar →
Observe the maximum admissible flow of 180 l/min!

Unit dimensions: Type 4WRE (dimensions in mm) Size 6

Required surface quality of the

valve mounting face

1 Valve housing
2 Proportional solenoid "a" with inductive position transducer
3 Proportional solenoid "b"
4 Mating connector "A", color gray,
separate order – see page 8
5 Mating connector "B", color black,
6 Mating connector for inductive position transducer,
7 Plug screw for valve with one solenoid
(2 spool positions, version EA or WA)
8 Identical seal rings for ports A, B, P, and T
9 Space required to remove the mating connector
10 Name plate
11 Machined valve mounting face,
porting pattern according to ISO 4401-03-02-0-05
(with locating hole)
Deviating from the standard:
- without locating hole "G"
- Ports P, A, B and T with Ø 8 mm
Subplates and valve mounting screws see page 22

Unit dimensions: Type 4WREE (dimensions in mm) Size 6


valve mounting face
General tolerances according to ISO 2768-mK

1 Valve housing
8 Identical seal rings for ports A, B, P, and T
10 Name plate
11 Machined valve mounting face,
porting pattern according to ISO 4401-03-02-0-05
(with locating hole)
Deviating from the standard:
- without locating hole "G"
- Ports P, A, B and T with Ø 8 mm
2
1 Integrated electronics (OBE)
13 Mating connector,

Unit dimensions: Type 4WRE (dimensions in mm) Size 10

valve mounting face

1 Valve housing
4 Mating connector "A", color gray,
5 Mating connector "B", color black,
6 Mating connector for inductive position transducer,
8 Identical seal rings for ports A, B, P, T and T1
9 Space required to remove the mating connector
10 Name plate
11 Machined valve contact surface,
porting pattern according to ISO 4401-05-04-0-05 differ-
ing from the standard: Connection T1 Ø 11.2 mm

Unit dimensions: Type 4WREE (dimensions in mm) size 10

valve mounting face

1 Valve housing
8 Identical seal rings for ports A, B, P, T and T1
10 Name plate
11 Machined valve contact surface,
porting pattern according to ISO 4401-05-04-0-05 differ-
ing from the standard: Connection T1 Ø 11.2 mm
2
1 Integrated electronics (OBE)
13 Mating connector,

22/22 Bosch Rexroth AG Hydraulics 4WRE; 4 WREE RE 29061/11.12
Unit dimensions
Hexagon socket head cap screws Material number

Size 6 4x ISO 4762 - M5 x 50 - 10.9-flZn-240h-L R913000064
Tightening torque MA = 7 Nm ±10 %
or
4x ISO 4762 - M5 x 50 - 10.9
Tightening torque MA = 8.9 Nm ±10 %
Size 10 4x ISO 4762 - M6 x 40 - 10.9-flZn-240h-L R913000058
or
4x ISO 4762 - M6 x 40 - 10.9
Notice: This tightening torque of the hexagon socket head cap screws refers to the maximum operating pressure!
Subplates Data sheet

Size 6 45052
Size 10 45054
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 may
Zum Eisengießer 1 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 application
documentation@boschrexroth.de can be derived from our information. The information given does not
www.boschrexroth.de 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.
RE 29061/11.12 4WRE; 4 WREE Hydraulics Bosch Rexroth AG 23/22
of wear and aging.
24/22 Bosch Rexroth AG Hydraulics 4WRE; 4 WREE RE 29061/11.12
of wear and aging.
Proportional RE 29158/04.05
Replaces: 11.02
1/12
pressure relief valve,

pilot operated
Types (Z)DBE and (Z)DBEE
Size 6
Component series 1X
Maximum operating pressure 315 bar
Maximum flow 30 L/min
H/A 3598/93

Contents Page – Valve for limiting a system pressure
Features 1 – Operation by proportional solenoid
Ordering code 2 – For subplate mounting or sandwich plate design:
Preferred types 2 Position of ports to DIN 24340 (without locating bore) and
ISO 4401 (with locating bore)
Symbols 3
Subplates to data sheet RE 45052
Function, section 3, 4 (separate order, see page 10 and 11)
Technical data 5, 6 – Valve and control electronics from a single source
Control electronics 6, 7 – External control electronics for types DBE and ZDBE:
Electrical connection, cable socket 6 • Analogue amplifier type VT-VSPA1-1 in Euro-card format
Characteristic curves 8, 9 (separate order), see page 6
Unit dimensions 10, 11 • Digital amplifier type VT-VSPD-1 in Euro-card format
(separate order), see page 6
• Analogue amplifier of modular design type VT 11131
(separate order), see page 6
– Integrated electronics (OBE) on types DBEE and ZDBEE:
• Low manufacturing tolerances for the command value/
pressure characteristic curve
• Up and down ramps can be adjusted independently of each
other
2/12 Bosch Rexroth AG Hydraulics (Z)DBE; (Z)DBEE RE 29158/04.05
Ordering code
DBE 6 1X G24 *
Subplate mounting = No code Further details

Sandwich plate =Z in clear text
Proportional pressure relief valve Seal material
For external control electronics = No code M= NBR seals,
With integrated electronics (OBE) =E suitable for mineral oil
Size 6 =6 (HL, HLP) to DIN 51524
V= FKM seals,
Subplate mounting = No code suitable for
Sandwich plate P → T = VP phosphate esters
Position of cable socket for type ZDBE Electrical connection
Position of housing with electronics (OBE) for type ZDBEE for DBE; ZDBE:
Housing with K4 = Without cable socket,
electronics (OBE) with component plug to
Cable socket DIN EN 175301-803
=1 1) =3 Cable socket– separate
order, see page 6
1) for DBEE; ZDBEE:
K31 = Without cable socket,
=2 =4 with component plug to
DIN EN 175201-804
1) 1) Cable socket– separate
1) Valve mounting side (R-ring recesses in the housing) order, see page 6
Component series 10 to19 = 1X Supply voltage of electronics
(10 to 19: unchanged installation and connection dimensions) G24 = 24 V DC
Max. set pressure No code = Internal pilot oil drain (recommen-
Pressure stage 50 bar = 50 dation: suplate mounting up to qVmax =15 L/min)
Pressure stage 100 bar = 100 Y= External pilot oil drain
Pressure stage 200 bar = 200 (possible only with subplate mounting)
Pressure stage 315 bar = 315
Preferred types
Type DBEE Type ZDBEE
Type Material no. Type Material no.

DBEE 6-1X/50YG24K31M R900954432 ZDBEE 6 VP2-1X/50G24K31M R900954434
DBEE 6 -1X/100YG24K31M R900919359 ZDBEE 6 VP2-1X/100G24K31M R900954435
Further preferred types and standard components

can be found in the EPS (standard price list).
RE 29158/04.05 (Z)DBE; (Z)DBEE Hydraulics Bosch Rexroth AG 3/12
Symbols (for sandwich plate symbol: 1 = component side, 2 = plate side)

Type DBE 6… Type DBE 6…Y.. Type ZDBE 6 VP…
1
T T
P P Y
P A 2 B T
Type DBEE 6… Type DBEE 6…Y.. Type ZDBEE 6 VP…
1
T T
P P Y
P A 2 B T
Function, section
Types DBE and ZDBE
Proportional pressure relief valves of types DBE and ZDBE are Via a further orifice (7) the system pressure acts on the pilot
operated by means of a proportional solenoid. These valves are poppet (8) against the force of the proportional solenoid (1).
used to limit a system pressure. With these valves it is possible Once the system pressure has reached the pre-set value, the
to infinitely adjust the system pressure to be limited in relation pilot poppet (8) lifts from its seat. Depending on the model,
to the electrical command value. pilot oil can now drain externally via port A (Y) or internally
These valves basically consist of a proportional solenoid (1), into the tank, which results in a limitation of the pressure on
housing (2), valve insert (3), spool (4) and pilot poppet (8). the spring-loaded side of the spool (4). If the system pressure
The proportional solenoid proportionally converts the electri- continues to rise slightly, then the higher pressure on the right
cal current into a mechanical force. An increase in the current hand side of the spool pushes the spool to the left into control
intensity causes a corresponding rise in the magnetic force. position P to T.
The solenoid armature chamber is filled with hydraulic fluid and At a minimum control current - corresponds to a command
is pressure-balanced. value of zero - the minimum settable pressure will be set.
The system pressure is adjusted by the proportional solenoid Note!
(1) in relation to the command value. Pressure applied by the To ensure optimim function, the valve must be bled during
system in port P acts on the right hand side of the spool (4). At commissioning:
the same time, the system pressure acts via the pilot line (6), – Remove bleed screw (9),
which is fitted with an orifice (5), on the spring-loaded side of – pour hydraulic fluid into the open threaded hole, item 9,
the spool (4). – when no more bubbles appear, re-fit screw, item 9.
– The tank should be prevented from draining. Where installa-
tion conditions allow, a pre-load valve should be installed
(pre-load pressure approx. 2 bar).
9 1 8 7 3 2 5 6 4 12
Type DBE ...K4...

A(Y) T P
Function, section
Types DBEE …K31… and ZDBEE …K31… – with integrated electronics (OBE)
10
11
In terms of function and design, these valves correspond to The command value/pressure characteristic curve (zero point
types DBE and ZDBE. An additional housing (10) is fitted on at the valve insert, see page 3, item 12, and the gradient on the
the proportional solenoid which accommodates the integrated Imax potentiometer (R30) in the electronics) is factory pre-set
electronics (OBE). Supply and command value voltages are with minor manufacturing tolerances.
connected to the cable socket (11). The ramp time for pressure build-up and pressure reduction
can be adjusted independently of each other using two poten-
tiometers.
For further information about the integrated electronics, see
page 7.
Technical data (for applications outside these parameters, please consult us!)
General
Weight – DBE and ZDBE kg 2.4
– DBEE and ZDBEE kg 2.5
Installation orientation Optional
Storage temperature range °C – 20 to + 80
Ambient – DBE and ZDBE °C – 20 to + 70
temperature range – DBEE and ZDBEE °C – 20 to + 50
Hydraulic (measured with HLP 46; ϑoil = 40 °C ± 5 °C)
Max. operating pressure – Port P; P1 – P2
A1 – A2; B1 – B2 bar 315
– Port T bar 50
Max. set pressure – Pressure stage 50 bar bar 50
– Pressure stage 100 bar bar 100
Min. set pressure at command value 0 bar See characteristic curve on page 9
Return flow pressure in port A; with external pilot oil drain (Y) Separate at zero pressure to tank
Pilot oil flow L/min 0.6 to 1.2
Max. flow L/min 30
Hydraulic fluid Mineral oil (HL, HLP) to DIN 51524.
Further hydraulic fluids on enquiry!
Hydraulic fluid temperature range °C – 20 to + 80
Viscosity range mm2/s 15 to 380
Max. permissible degree of contamination of the hy- Class 20/18/15 1)
draulic fluid - cleanliness class to ISO 4406 (c)
Hysteresis % ± 1.5 of max. set pressure
Repeatability % < ± 2 of max. set pressure
Linearity % ± 3.5 of max. set pressure
Tolerance of the command – DBE and ZDBE % ± 2.5 of max. set pressure
value/pressure curve, – DBEE and ZDBEE % ± 1.5 of max. set pressure
referred to the hysteresis curve, increasing pressure
Step response Tu + Tg 10 % → 90 % ms approx. 80
depends on system
90 % → 10 % ms approx. 50
1) The cleanliness classes specified for components must be
adhered to in hydraulic systems. Effective filtration prevents
malfunction and, at the same time, increases the service life
of components.
For the selection of filters, see data sheets RE 50070,
RE 50076, RE 50081, RE 50086 and RE 50088.
Electrical
Supply voltage V 24 DC
Min. control current mA 100
Max. control current mA 1600
Coil resistance – Cold value at 20° C Ω 5.4
– Max. hot value Ω 7.8
Duty cycle % 100
Electrical connection – DBE and ZDBE With component plug to DIN EN 175301-803
Cable socket to DIN EN 175301-803 2)
– DBEE and ZDBEE With component plug to DIN EN 175201-804
Cable socket to DIN EN 175201-804 2)
Type of protection of the valve to EN 60529 IP 65 with cable socket mounted and locked
Control electronics
– For DBEE and ZDBEE Integrated in the valve, see page 7
– For DBE and ZDBE
Amplifier in Euro-card format analogue VT-VSPA1-1 according to data sheet RE 30111
(separate order) digital VT-VSPD-1 according to data sheet RE 30123
Amplifier of modular design (separate order) analogue VT 11131 according to data sheet RE 29865
2) Separate order, see below
Note: For details regarding environment simulation climate and mechanical stress, see RE 29158-U (declaration
testing in the fields of EMC (electromagnetic compatibility), on environmental compatibility).
Electrical connection, cable sockets (nominal dimensions in mm)

For types DBE and ZDBE – for external control electronics
27,5
Cable socket to DIN EN 175301-803
Separate order: Material no. R901017011 10A
250V 2
18
Connection to component plug Connection to cable socket

GDM
43 10 2
PE PE
34,2
1 2 1 2
to amplifier
1
5,5
For types DBEE and ZDBEE – with integrated electronics (OBE) 1 Fixing screw M3
Cable socket to DIN EN 175201-804 Tightening torque MT = 0.5 Nm
Separate order: Material no. R900021267 (version made of plastic)
91
Ø27
A
F
B
C E
D
Ø6,5…Ø11
For the pin assignment, see block circuit diagram on page 7

Integrated electronics (OBE) for types DBEE, ZDBEE
Function
The integrated electronics is controlled via the two differential The current regulator controls the solenoid current independ-
amplifier connections D and E. ently of the solenoid coil resistance.
The ramp generator generates from a command value step The gradient of the command value/current characteristic
change (0 to 10 V or 10 to 0 V) a delayed rise or drop in the curve, and hence also the gradient of the command value/
solenoid current. The rise time of the solenoid current can pressure characteristic curve of the proportional pressure valve
be adjusted by means of potentiometer R14, the drop time by may be altered using potentiometer R30.
means of potentiometer R13. Potentiometer R43 is used to adjust the biasing current. This
The maximum ramp time of 5 s is only possible over the entire setting should not be altered. If necessary, the zero point of the
command value range. With smaller command value changes command value/pressure characteristic curve can be adjusted
the ramp time shortens accordingly. at the valve seat.
The command value/solenoid current characteristic curve is The power stage of the electronics for controlling the propor-
matched to the valve by the characteristic curve generator, so tional solenoid is a chopper amplifier. It is pulse-width-modu-
that non-linearities in the hydraulics can be compensated for lated with a clock frequency of 300 Hz.
and hence a linear command value/pressure characteristic The solenoid current can be measured at the two measurement
curve is obtained. sockets MP1 and MP2. A voltage drop of 0.352 V at the meas-
urement resistor corresponds a to solenoid current of 1.6 A.
Block circuit diagram / pin assignment of integrated electronics
Differential Ramp Char. curve +U Chopper

Current
amplifier generator generator regulator amplifier
D R 14 R 13 Imax Imin
Command value 0 to 10 V + U
R 30 I R 43
E U
0V reference potential – Solenoid
F n.c. Ramp Ramp
"up" "down"
Supply voltage: C n.c.
+U MP1
Ueff: 22 to 33 V 300 Hz
A +7,5 V Measuring resis- 1,6 A =
+ = tor R=0.22 Ω 0,352 V
Internal reference point
B = MP2
0V = -7,5 V
Oscillator
Power supply unit 0V
Supply voltage
Power supply unit with rectifier
Single phase rectification or three phase bridge: Ueff = 22 to 33 V
Residual ripple content at power supply unit: < 5 %
Output current: Ieff = max. 1.4 A
Supply cable: – Recommended: 5-core 0.75 or 1 mm2
with PE conductor and shield 30 0,75 mm2
Min. supply voltage in V →
– Outside diameter 6.5 to 11 mm

– Shield to 0 V supply voltage 28
1 mm2
– Max. permissible length 100 m
26
The minimum supply voltage of the power supply unit depends
on the length of the supply cable (see diagram). 24
For lengths > 50 m a capacitor of 2200 µF must be installed
near the valve in the supply line. 22
20 40 60 80 100
Length of supply cable in m →
Characteristic curves (measured with HLP 46; ϑoil = 40 °C ± 5 °C )

Pressure in port P or P2 in dependence upon the command value (qV = 5 L/min)
Pressure stage 50 bar (external and internal) Pressure stage 100 bar (external and internal)
60 120
Pressure in P or P2 in bar →
50 100
40 80
30 60
20 40
10 20
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
Command value in % → Command value in % →
Pressure stage 315 bar (external and internal)
350
Pressure stage 200 bar (external and internal)
240 300
200 250
160 200
120 150
80 100
40 50
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
Command value in % → Command value in % →
Pressure stage 50 bar Pressure stage 100 bar
60 125
50 100
40 75
30 50
20 25
10
0 5 10 15 20 25 30
Flow in L/min →
0 5 10 15 20 25 30
Pressure stage 315 bar
Flow in L/min → 400
350
300
Pressure stage 200 bar
250 250
200 200
150 150
100 100
50 50
0 5 10 15 20 25 30 0 5 10 15 20 25 30
Flow in L/min → Flow in L/min →
The characteristic curves were measured without backpressure in port A (external pilot oil drain) and T (internal pilot oil drain).
With internal pilot oil drain the pressure in P or P2 increases by the output pressure present in port T.
Characteristic curves (measured with HLP 46; ϑoil = 40 °C ± 5 °C )

Min. set pressure in port P or P2 at command value 0. Pilot oil drain –––––– internal – – – external
14 14
Min. set pressure in bar →

12 12
10 10
8 8
6 6
4 4
2 2
0 5 10 15 20 25 30 0 5 10 15 20 25 30
14 14

12 12
10 10
8 8
6 6
4 4
2 2
10 0 15 5
20 25 30 0 5 10 15 20 25 30
The characteristic curves were measured without backpressure in port A (external pilot oil drain) and T (internal pilot oil drain).
With internal pilot oil drain the pressure in P or P2 increases by the output pressure present in port T.
Pressure differential A1 → A2 and B1 → B2 Pressure differential P1 → P2

5 5
Pressure differential in bar →
4 4
3 3
2 2
1 1
0 5 10 15 20 25 30 0 5 10 15 20 25 30
Pressure differential T1 → T2
5
0 5 10 15 20 25 30
Flow in L/min →
Unit dimensions: Types DBE and DBEE (nominal dimensions in mm)
271 (with integrated electronics)
204,9
7 6 9 3 8
Ø 10
15
Ø 5,5
87
1,3+0,1
50
42
Ø 12,2+0,1
2 1 4 5
199,6 (71,4)
133,5
43,5
T
A B
P 45
99,4
10 103
45
F1 T F2
0,01/100mm
8
A B
47
Rzmax 4
F4 P G F3
Required
1 Valve housing surface quality
of the mating part
2 Proportional solenoid
3 Nameplate Tolerances to: – General tolerances ISO 2768-mK
4 Identical seal rings for ports A, B, P and T – Tolerancing principle ISO 8015
5 With version Y, pilot oil drain external via port A (Y)
6 Cable socket for type DBE
(separate order, see page 6)
7 Cable socket for type DBEE Subplates to data sheet RE 45052 and valve fixing screws
(separate order, see page 6) must be ordered separately.
8 Space required to remove cable socket Subplates: G 341/01 (G 1/4)
9 Integrated electronics (OBE) G 342/01 (G 3/8)
10 Machined mounting face, position of ports to G 502/01 (G 1/2)
DIN 24340 (without locating bore) and Valve fixing screws:
ISO 4401 (with locating bore) 4 socket head cap screws M5 x 50 DIN 912 10.9
Tightening torque MT = 7 Nm
Unit dimensions: Types ZDBE and ZDBEE (nominal dimensions in mm)
271 (with integrated electronics)

204,9
8 9 6 7
"1"
15
Ø 5,5
87
50
"3"
4 10 3 1 2
30,5 (240,5)
11 (174,4)
"2"
62
T
F1 F2
A B
45
F4 P F3
62
99,4
"4"
"1" to "4" – position of cable socket or housing with integrated electronics (see ordering code)
Required 0,01/100mm
surface quality Rzmax 4
of the mating part
1 Valve housing
2 Proportional solenoid
Tolerances to: – General tolerances ISO 2768-mK
3 Nameplate
– Tolerancing principle ISO 8015
4 Identical seal rings for ports A, B, P and T
6 Cable socket for type ZDBE
Subplates to data sheet RE 45052 and valve fixing screws
7 Cable socket for type ZDBEE must be ordered separately.
Subplates: G 341/01 (G 1/4)
8 Space required to remove cable socket G 342/01 (G 3/8)
9 Integrated electronics (OBE) G 502/01 (G 1/2)
10 Machined mounting face, position of ports Valve fixing screws:
nach DIN 24340 (without locating bore) and 4 socket head cap screws M5 DIN 912 10.9
ISO 4401 (with locating bore) Tightening torque MT = 7 Nm
Notes
Bosch Rexroth AG © This document, as well as the data, specifications and other
Hydraulics information set forth in it, are the exclusive property of Bosch Rexroth
Zum Eisengießer 1 AG. Without their consent it may not be reproduced or given to third
97816 Lohr am Main, Germany parties.
Phone +49 (0) 93 52 / 18-0 The data specified above only serve to describe the product. No
Fax +49 (0) 93 52 / 18-23 58 statements concerning a certain condition or suitability for a certain
documentation@boschrexroth.de application can be derived from our information. The information given
www.boschrexroth.de 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.
Analogue command value module RE 29902/05.14
Replaces: 07.05
1/6
Type VT-SWMA-1
Series 1X
H5999

Contents Page – Suitable for controlling valves with integral electronics
Features 1 – Possibility of realising simple hydraulic functions via digital
Ordering code, preferred types 2 controlling
Functional description 2 – Adjustment elements:
1 potentiometer for zero point adjustment
Block circuit diagram / pin assignment 3
(command value offset)
Technical data 4 1 potentiometer for command value attenuation
Terminal assignment 5 (for differential input)
Unit dimensions 5 4 potentiometers for command value preselection
5 potentiometers for ramp time adjustment
Engineering / maintenance notes / supplementary information 6
– LED lamps: Command value call-up (4 x)
Active ramp time (4 x)
Quadrant recognition
Polarity reversal
Power
– Measuring sockets for command value and ramp time
– Differential input
– 4 call-up possibilities each for command value and ramp time
– Ramp generator with 5 ramp times; 4-quadrant recognition
– Control signal output
– Power supply unit without raised zero point
– Without power part
2/6 Bosch Rexroth AG Hydraulics VT-SWMA-1 RE 29902/05.14
Ordering code
VT-SWMA-1 1X V0 0 *
Analogue command value module Further details in clear text

Series 10 to 19 = 1X 0 = Basic version
(10 to 19: unchanged technical data V0 = Basic version
and pin assignment)
Functional description
General As long as the signal is being changed, the LED assigned to

The command value module is to be snapped onto top hat rails the current ramp is alight.
to EN 60715. The electrical connection is made using screw- Ramp time call-ups [11]
type terminals. The module is operated with 24V DC voltage.
A power supply unit [1] provides the internally required positive When quadrant recognition is not activated, a separate ramp
and negative supply voltages. The green LED (power) lights up time “t1” to “t4” is assigned to each command value call-up
as soon as the power supply unit is in operation. “w1” to “w4”.
As long as a signal is being changed, the LED assigned to the
Internal command value current ramp time is alight.
The internal command value is generated from the external
command value signal applied to differential input [2], a called Ramp time “t5“ [12]
up signal and an offset signal (zero point potentiometer “Z“ If neither quadrant recognition nor a call-up is activated, ramp
[3]). time “t5” is always valid. This ramp time can be used, among
The external command value signal can be changed from 0 % others, for an emergency stop function. The valve can be
to approx. 110 % by means of potentiometer “G“ (amplitude at- closed with the defined ramp time “t5“.
tenuator [4]). Ramp time adjustment
Command value call-ups The current ramp time can be checked at measuring socket “t“
Call-up signals w1 to w4 [5] can also be adjusted between 0 [13]. Ramp times “t1” to “t4” can be adjusted with the help of
% and 110 %. Call-up signals w1 and w2 have a positive, call- the ramp time potentiometers. Through activation of a call-up
up signals w3 and w4 a negative polarity. This allows the rea- signal, ramp time signal “t” at the measuring socket is clear-
lisation of two forward and two reverse movements of the hy- ly assigned to one of the ramp times t1 to t4. t5 is assigned to
draulic drive without requiring any additional circuitry. For appli- the ramp time signal at the measuring socket, if neither a call-
cations that require more than two signals of the same polarity, up nor quadrant recognition is activated. The adjustment range
command value inversion is provided [6]. If this is activated, for of the ramp time is selected so that these can be set reprodu-
example, together with call-up 3, call-up signal w3 also provi- cibly (for details, see “Technical data”).
des a positive control variable. Output
Only 1 call-up is possible at a time. If several call-ups are acti- The output signal of the ramp generator can be checked at
vated simultaneously, the following is valid: Call-up “1“ has the measuring socket “w“ [14]. The downstream matching amplifier
lowest priority, call-up “4“ has the highest priority [7]. [15] provides the control signal for the valve via output “control
Quadrant recognition variable” [16].
When quadrant recognition [8] is activated, the electronics

automatically recognises the polarity [9] and any changes (up/ [ ] = Cross-reference to block circuit diagram on page 3
down) [10] in the control variable and assigns a ramp time to
the current signal state.
Ramp Polarity of- Signal changes

time control output in direction of…
t1 + Maximalwert 0% Maximum
value (+)
Maximum 0%
t2 + 0%
value (+)
Maximum
t3 – Maximalwert 0% value (–)
Maximum
t4 – 0% value (–) 0%
Command value inversion 6
Inv
Differential input: 2
5
Command value ± 10 V u Z
14
RE 29902/05.14
Reference potential 4 u G w
–Uref 4 3
–Uref 5
+Uref w4
g d 7 Control
+Uref w3 ±1
t
S a b variable
w2 6 15
VT-SWMA-1
w1
8 Reference
7 potential
9
Call-up command value 1 13
t
10
Call-up command value 2
11
12
Block circuit diagram / pin assignment

+/– 9
10
3 8
Quadrant operation Ramp time selection logic
4-Q
a b g d
+ 15 V
1
t1 t2 t3 t4 t5 12
1
+U
+ U0B DC – 15 V 11
Operating + Uref
voltage 2 – Uref
0V DC
L0 M0
1 Power supply unit 6 Command value inversion 11 Ramp time call-ups

2 Differential amplifier 7 Priority logic 12 Ramp time potentiometer “t5“
3 Summator with zero point 8 Quadrant recognition 13 Measuring socket “ramp time signal“
potentiometer 9 Polarity recognition 14 Measuring socket “internal command value“
4 Amplitude attenuator 10 Recognition of changes in the 15 Matching amplifier
Hydraulics Bosch Rexroth AG
5 Call-up signals contol variable (up/down)

3/6
Operating voltage Uo 24 VDC +40 % –10 %

Operating range:
– Upper limit value uo(t)max 35 V
– Lower limit value uo(t)min 18 V
Power consumption PS 12 VA
Current consumption Imax 0.5 A
Fuse Thermal overload protection
(reactivation when temperature falls below threshold)
Inputs
– Command value (differential input with attenua- Ui 0 to ±10 V; Ri > 50 kΩ
tor)
– Quadrant operation “4-Q“
• active U4-Q 8.5 V to 35 V; Ri > 50 kΩ
• inactive U4-Q 0 to 6.5 V
– Command value inversion “Inv“
• active UInv 8.5 V to 35 V; Ri > 50 kΩ
• inactive UInv 0 to 6.5 V
– Command value call-ups 1 to 4
• active U 8.5 V to 35 V; Ri > 50 kΩ
• inactive U 0 to 6.5 V
Adjustment ranges:
– Zero balancing (potentiometer “Z“) ±30 %
– Amplitude attenuator (potentiometer “G“) 0 % to ca. 110 %
– Command values (potentiometers “w1“ to “w4“) 0 % to ca. 110 % (factory setting 100 %)
– Ramp times (potentiometers “t1“ to “t5“) 20 ms to 5 s
Outputs:
– Control variable U 0 to ±10 V; ±6 mA; RL > 5 kΩ
– Measuring socket for control variable “w“ Uw 0 to ±10 V (+100 % ≙ +10 V; –100 % ≙ –10 V)
– Measuring socket for ramp time “t“ Ut 0,01 V to +10 V 0,01 V(tmax  ca. 10 s); 10 V(tmin  ca. 10 ms)
Type of connection 12 screw terminals
Type of mounting Top hat rail TH 35/7.5 to EN 60715
Type of protection IP 20 to EN 60529
Dimensions (W x H x D) 40 x 79 x 85,5 mm
Permissible operating temperature range ϑ 0 to +50 °C
Storage temperature range ϑ –25 to +85 °C
Weight m 0.3 kg
Note:
For details regarding environment simulation tests in the field
of EMC (electro-magnetic compatibility), climate and mechanical
stress, see RE 29902-U (declaration on environmental
compatibility).
RE 29902/05.14 VT-SWMA-1 Hydraulics Bosch Rexroth AG 5/6
Note on the adjustment and measurement of the ramp time

For adjusting the ramp time potentiometers we recommend that
4-quadrant recognition be switched off and call-ups be activated.
Value at measuring socket “t“ Ut in V 5 3 2 1 0,5 0,3 0,2 0,1 0,05 0,03 0,02
Current ramp time (± 20 %) t in ms 20 33 50 100 200 333 500 1000 2000 3333 5000
100 V ms Example: Measured Ut = 5 V

The following is valid: t=
Ut
100 V ms
Results in t= = 20 ms
5V
Terminal assignment
+U0 1 7 Control variable

Operating output
voltage Reference
0V 2 8
potential
Quadrant
+U4-Q 3 9 Call-up command value 1
operation
Reference
potential 4 10
Differential
input
±Ucomm 5 11 Call-up command value 3
Command va- Call-up command value 4

+UInv 6 12
lue inversion
Unit dimensions (Dimensions in mm)
Top hat rail TH 35-7.5

to EN 60715
7 8 9 10 11 12 Potentiometers (some with LED lamps):

“t1“ to “t5“ → Ramp times
REXROTH “w1“ to “w4“ → Command value call-ups
VT-SWMA-1 “G“ → Amplitude attenuator for
4-Q Inv differential input
t1 w1 “Z“ → Zero point balancing
t2 w2
79
t3 w3 LED lamps:
t4 w4 “4-Q“ → Quadrant recognition
t5 G “Inv“ → Inversion active
t w Z green → Ready for operation “power“
(no lettering)
1 2 3 4 5 6 Measuring sockets:
“t“ → Current ramp time
85,5 40 “w“ → Internal control variable
“⊥“ → Reference potential / ground
Engineering / maintenance notes / supplementary information
– The amplifier module may only be unplugged when disconnected from the power supply!
– Ensure a sufficient distance to aerial lines, radio sources and radar equipment (>> 1 m)!
– Shield command value lines, do not lay near power cables!
– Caution: When the differential input is used, both inputs must be activated or deactivated simultaneously!
Note: Electrical signals (e.g. control variable) brought out via control electronics must not be used
for switching safety-relevant machines functions!
(See also the European standard “Safety requirements for fluid power systems and components
– hydraulics”, EN 982)
Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Zum Eisengießer 1 reproduced or given to third parties without its consent.
Telefon +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain application
Telefax +49 (0) 93 52 / 18-23 58 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.
RE 29902/05.14 VT-SWMA-1 Hydraulics Bosch Rexroth AG 7/6
Notizen
wear and aging.
Notizen
wear and aging.
General product information on RE 07008/02.05 1/32
hydraulic products
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DA Dit sprog? – Se bagside!
EL Η γλώσσα σα; – Βλέπε πίσω πλευρά!
2/32 Bosch Rexroth AG Hydraulics General product information RE 07008
Contents Page
1 Important basic information 4
1.1 Conventions used in this product information 4
1.2 What you need to know about this product information 4
1.3 The contents of this product information 4
2 Scope of delivery and responsibilities 5

2.1 Scope of delivery and responsibilities of Bosch Rexroth 5
2.2 Responsibilities of the plant operator 5
2.3 Liability, guarantee, warranty 6
2.4 Copyright 6
3 Important basic safety instructions 7

3.1 What to do in an emergency 7
3.2 Safety labelling on the hydraulic product 7
3.3 Proper use 7
3.4 Requirements for personnel, duty of care 8
3.5 General ancillary dangers and protective measures
when operating hydraulic products 9
4 Technical data and ambient conditions 11

4.1 Information about pressure fluids 11
4.2 Ambient conditions 11
5 What you need to know about pressure fluids 13

5.1 How to handle pressure fluids safely 13
5.2 Functions and effectiveness 13
5.3 Viscosity 13
5.4 Leakage fluid 14
5.5 Topping up/refilling 14
6 Construction and mode of operation of a hydraulic system 15

6.1 Definitions of terms 15
6.2 Schematic 15
6.3 Safety concept 15
7 Moving hydraulic units/components 16
8 Storage and longer standstills 16

8.1 Hydraulic systems - subsequent bringing into use after storage 16
8.2 Seals, hoses and hose lines 17
RE 07008 General product information Hydraulics Bosch Rexroth AG 3/32
Contents Page
9 Assembly and bringing into first use 18
9.1 Safety advice for assembly and bringing into first use 18
9.2 Before bringing into first use 18
9.3 Bringing into first use, subsequent bringing into use 19
10 Operation 22
11 Trouble-shooting 22
11.1 What to do in the event of a fault 22
11.2 The basic approach to trouble-shooting 22
11.3 Trouble-shooting tables 23
12 Maintenance 24
12.2 Safety during maintenance tasks 24
12.3 Inspection and servicing 25
12.4 Service and storage lives of hose lines 28
12.5 Topping up the pressure fluid 29
12.6 Servicing pressure accumulators 29
12.7 Repair 29
13 General information about hydraulic pressure accumulators 30

13.1 General 30
13.2 Safety devices relating to hydraulic pressure accumulators 30
14 Hydraulic systems 31
14.1 Effects of leaks in the hydraulic system on the machine 31
1 Important basic information Observing the product information and Operating Instructions
Ø reduces downtimes and maintenance costs
Ø increases the service life of your hydraulic products.
1.1 Conventions used in this product
information
The Operating Instructions must be directly accessible to one
Cross-references are printed in italics. of the personnel at the hydraulic product and kept readily avail-
able at all times in a place known to the personnel.
The Operating Instructions must be read and understood and
all its provisions observed by those responsible and by the
DANGER operative personnel. We recommend that a record is made in
writing of the employees’ familiarisation with all the relevant
This symbol indicates a threat of danger which will result parts.
directly in death or very serious injury if not avoided.
The cross-references to directives, standards and regulations
contained in this product information refer to the versions cur-
rent at the time of writing of this product information, which can
WARNING be obtained from the title page of this product information.
This symbol indicates a threat of danger which may result

in death or very serious injury if not avoided. 1.3 The contents of this product information
In addition to this document, product information for Rexroth

hydraulic products normally includes Operating Instructions
CAUTION consisting of three parts:
This symbol indicates possible danger which may lead to Ø Part I, the general Operating Instructions for the relevant
minor or serious injury and/or to material damage. class of products
Ø Part II, the Technical Datasheet
IMPORTANT Ø Part III, the Product- and Application-specific Operating

Instructions.
This symbol indicates additional information.
If you do not have all three parts, please request the missing
1.2 What you need to know about this part from Bosch Rexroth. Only if all the information contained
product information in all parts of the three-part Operating Instructions is observed
can safe operation of Rexroth hydraulic products be ensured.
This product information applies to the following types of Specific cross-references are used to draw your attention to
hydraulic products: information that you can find in the Operating Instructions.
Ø Hydraulic components The Operating Instructions contain detailed information about
Ø Hydraulic power units the product, including
Ø Hydraulic systems. Ø Information about the scope of delivery

Ø Safety instructions
This product information applies exclusively to hydraulic prod- Ø Technical data and operating limits
ucts that are operated with mineral-oil-based pressure fluids, if
the Operating Instructions do not expressly permit the use of Ø Information about bringing into (first) use and maintenance
other pressure fluids. Ø Information about the mode of operation
IMPORTANT Ø Layouts, drawings
As this product information for Rexroth hydraulic products Ø Parts lists if appropriate
applies in a general sense, some of the content may not neces- Ø Information about replacement parts and accessories.
sarily apply to the hydraulic product you have purchased.
However, only by strictly observing this product information
and the Operating Instructions can accidents be prevented
and problem-free operation of your Rexroth hydraulic product
be guaranteed.
2 Scope of delivery and responsibilities Installation of Rexroth hydraulic products in a machine or sys-
tem may increase this value, and if so, the manufacturer of the
machine/system must document this.
2.1 Scope of delivery and responsibilities of At or above 85 dB(A), the plant operator must make suitable
Bosch Rexroth hearing protection available to the personnel.
Rexroth hydraulic products fulfil all safety requirements applica- 2.2.2 Special points concerning the installation of
ble to fluid power systems and their components.
certain products
IMPORTANT A Rexroth hydraulic product is intended above all for installa-
For the scope of delivery and the responsibilities of tion in machines, systems and power units as a part machine
Bosch Rexroth with respect to the product, please refer to the or a component for installation into another machine or system
Product-specific Operating Instructions. and is not a complete machine in the sense of the EU directive.
In addition to the Machinery Directive, still further directives
may apply, such as the Pressure Equipment Directive or the
Explosion Protection Directive.
2.2 Responsibilities of the plant operator A wide range of dangers can arise from the combined actions
of the hydraulic product and the machine or system in which
the hydraulic product is installed. Therefore you must always
CAUTION make sure that the hydraulic product is also suitable without
restriction for the proposed application at the installation loca-
If Rexroth hydraulic products are positioned in the vicinity tion. The interfaces with the overall machine and the operat-
of sources of ignition or strong radiators of heat, protec- ing conditions are also of the greatest importance. We recom-
tion must be put in place that would prevent any escaping mend that the results of the hazard analysis (risk assessment)
pressure fluid from igniting and the hose lines from aging of the overall machine are taken into account in the design of
prematurely. the hydraulic product.
Mineral-oil-based pressure fluid is hazardous to water and The functioning of the hydraulic product is also influenced by
flammable. It may only be used if the relevant safety data- the machine or system in which it is installed.
sheet from the manufacturer is available and all the mea- For this reason, you must also always observe the Operating
sures stipulated therein have been implemented. Instructions of the overall system in which your hydraulic prod-
If there is a risk of fluid leaking from the hydraulic product is installed. It is most important for you to also consider the
uct and contaminating water or the ground, the hydraulic possible use of the hydraulic product in a potentially explosive
product in question must be placed in a suitable collect- atmosphere (see 94/9/EC).
ing trough. In connection with this, the applicable statutory
regulations must be observed. IMPORTANT
You must also observe the EU directives for the use of work Bosch Rexroth points out that, at the time of their first intro-
equipment (Directive 89/391/EC) and the associated individ- duction on to the market, hydraulic products comply with the
ual directives, especially Directive 1999/92/EC for the protection requirements of all relevant EU directives and/or their imple-
from the danger arising from potentially explosive atmospheres mentation into national legislation in Germany. If the scope of
and their implementations in national legislation. The legisla- delivery is intended to be installed in a machine or system, then
tion contains minimum requirements with respect to the making the Machinery Directive applies as appropriate – including the
available by the employer of work equipment and for the use then currently applicable amendments – in that the scope of
of work equipment by employees at work, including the regu- delivery does not necessarily comply with the requirements
lations for operating equipment requiring supervision and the of the Machinery Directive because the scope of delivery is
obligation to produce explosion protection documentation. This intended for installation in a machine or because the scope of
involves, for example, dividing areas endangered by potentially delivery is intended for combination with other machines into a
explosive atmospheres into zones and specifying suitable work machine or a hydraulic system.
equipment and procedures for these areas. The bringing into use of the scope of delivery shall there-
fore not be permitted until the machine or system in which the
scope of delivery is to be installed or of which it represents a
2.2.1 Noise protection
component complies with the requirements of all relevant EU
directives.
The A-weighted equivalent continuous sound power level of
Rexroth hydraulic products can be obtained from the relevant Details of further responsibilities can be found in
Operating Instructions. If no values are documented then it can 3 Important basic safety instructions and in the Operating
be taken that the value is less than 70 dB(A). Instructions.
2.3 Liability, guarantee, warranty
Bosch Rexroth shall not be liable for damages that result from
non-compliance with or disregard of these and other parts of
the Operating Instructions.
Unauthorised tampering shall render the warranty null and void.
Bosch Rexroth shall only be liable if the scope of delivery was
shown to be defective. Bosch Rexroth shall not be liable if a
deficiency occurs that involves parts having been replaced by
the customer with equivalent but not identical parts as speci-
fied by the manufacturer.
Please refer to our general terms of supply or your contract for
details of the guarantee and manufacturer’s warranty.
2.4 Copyright
This product information may only be reproduced – electroni-

cally or mechanically, in whole or in part – with the express writ-
ten permission of Bosch Rexroth. It may likewise not be distrib-
uted, amended, transmitted, translated into another language
or employed or copied for other purposes or by other parties
without such consent.
3 Important basic safety instructions IMPORTANT

The hydraulic product shall be operated exclusively with pres-
sure fluids complying with DIN 51524. Where other pressure
3.1 What to do in an emergency fluids are permitted, for example brake fluids for brake valves,
this is specially mentioned in the Operating Instructions.
In the event of an emergency, fault or other abnormal occur-
For details on proper use see 4 Technical data and ambient
rences:
conditions.
1. Switch off the hydraulic system.
The following information can be found in the Operating
2. Secure the main switch against being unintentionally Instructions:
switched on again.
Ø the proper use, specific to the hydraulic product
3. Secure the danger area so that no one can enter the dan-
Ø where applicable, the safety category in accordance with
ger area unknowingly or uncontrolled.
EN 954-1
4. Notify the relevant specialist personnel immediately.
Ø non-permitted and improper use.
5. In the event of fire, observe the provisions of the safety
datasheets issued by the manufacturer of the pressure
fluid and the fire precautions specifically applicable to
your place of work, which must be documented in the 3.3.1 Proper use, requirements before operation
plant operator’s operating manual.
Ø Rexroth hydraulic products may only be operated if they
are in perfect technical condition.
WARNING • In the event of disturbances in the power supply and/

or damage to the electrical equipment, switch off
immediately and secure the main switch against being
Fighting fires with materials other than those permitted switched on again without authorisation.
can lead to explosions and/or more rapid spread of the
fire! • Report and rectify all faults and damage indicated by
Danger to life from smoke inhalation! the system or discovered by other means.
Ø The connections, operating conditions and performance
data specified in the Operating Instructions must be
observed and never changed.
3.2 Safety labelling on the hydraulic product Ø Rexroth hydraulic products shall not be converted or
otherwise modified without prior consultation with
IMPORTANT Bosch Rexroth.
Ø The meanings of the safety labelling on the Rexroth prod- Ø The plant operator shall not modify the program code of
uct are explained in the Operating Instructions. programmable control systems.
Ø For a diagram of the nameplate and an explanation of the Ø Dependencies and time factors shall not be modified with-
information on it please refer to the Operating Instructions. out prior consultation.
Ø The safety devices fitted by Rexroth must be present,
properly installed and in full working order – except when
this is impractical during setting up or maintenance work.
3.3 Proper use They shall not be relocated, bypassed or rendered ineffec-
tive.
Rexroth hydraulic products are designed and constructed for
the provision, transmission, control or regulation of energy and Ø Safety components such as limit switches, valves and
signals using the flow of oil. other control components shall not be rendered inopera-
tive.
Unless otherwise agreed, the Rexroth hydraulic product satis-
fies at least safety category B in accordance with EN 954-1. Ø Tamperproof lead seals installed by the manufacturer shall
not be removed or damaged except when this is neces-
If the hazard analysis/risk assessment of the overall machine sary in the course of maintenance tasks defined in the
in which the Rexroth hydraulic product is to be installed indi- Operating Instructions.
cates that a safety category higher than category B in accor-
dance with EN 954-1 is required for the Rexroth hydraulic Ø The specified maintenance tasks in the Operating Instruc-
product, then a correspondingly higher rated hydraulic product tions shall be carried out at the intervals stated in the
can be supplied and installed only after special agreement with Operating Instructions.
Bosch Rexroth.
Ø Uncontrolled access by persons unfamiliar with the sys- Servicing personnel (who carry out filter and oil changes, for
tem to the immediate operating zone of Rexroth hydraulic example) shall fulfil the following requirements:
products is prohibited (even if the product in question has
Ø They have been instructed in the relevant activity.
been shut down).
Ø Specialist knowledge of hydraulics is not required to carry
Ø Rexroth hydraulic products must never be assembled,
out servicing work.
operated or maintained by persons under the influence of
alcohol, drugs or other medication which affect one’s abil-
ity to react. Repair personnel shall fulfil the following requirements:
Ø The personnel must be hydraulics experts, who have been
instructed and meet the definition given above,
3.4 Requirements for personnel, Ø Repair personnel must be familiar with the function of the
duty of care hydraulic system as a whole, from subsystems to their
interaction with the function of the entire machine.
Ø Repair personnel must be able to read hydraulic circuit
3.4.1 Qualifications of specialist personnel diagrams, interpret individual functions from their symbols
and understand function diagrams.
A specialist person is someone who, using his specialist train-
ing, knowledge and experience as well as familiarity with the Ø Repair personnel must possess knowledge of the function
relevant conditions, can and construction of hydraulic elements.
Ø safely carry out the tasks allocated to him and correctly

assess the scope and implications of his work
3.4.3 Requirements for electrical maintenance
Ø recognise possible dangers
personnel
Ø undertake the necessary measures to eliminate possible
accidents. All work on electrical equipment shall only be carried out by
an authorised, qualified electrician, or by instructed persons
under the guidance and supervision of a qualified electrician, in
accordance with the rules applicable to electrotechnical prod-
3.4.2 Requirements for hydraulics maintenance ucts.
personnel
In accordance with DIN 31051, maintenance comprises the

individual activities of inspection, servicing and repair. All
3.4.4 Minimum age
personnel involved in maintenance shall be familiar with and
observe all parts of the Operating Instructions and this product
Persons under the age of 18 who are currently receiving
information.
instruction or training or are working under supervision may not
Inspection personnel shall fulfil the following requirements: work on Rexroth hydraulic products.
Ø They have been instructed in the relevant activity. This does not apply to young persons of 16 or over if
Ø Specialist knowledge of hydraulics is not required for Ø working on Rexroth hydraulic products is necessary in
purely inspection activities but the personnel must be order for them to accomplish a training objective
aware of the particular dangers associated with hydraulic
Ø their protection is guaranteed by the supervision of an
products.
experienced, competent person
Ø they are allowed to use only tools, work implements and
protective gear that preclude the risk of injury.
3.4.5 Training 3.5.1 Dangers from pressure fluid
The plant operator using Bosch Rexroth hydraulic products

shall train his personnel regularly in the following subjects: CAUTION
Ø Observation and use of the Operating Instructions and
legal requirements Handling pressure fluid without protection is hazardous to
health.
Ø Proper operation of the Rexroth hydraulic product
Please observe the manufacturer’s safety instructions and the
Ø Observation of the instructions of safety officers and the safety datasheets for the pressure fluid that you are using.
plant operator’s operating manual
Ø What to do in an emergency. DANGER
IMPORTANT Serious damage to health or death may result if pressure fluid
Bosch Rexroth can provide you with training support in special- enters the blood stream or is swallowed. If this occurs, contact
ist areas. a doctor immediately!
An overview of the training can be found on the Internet at

http://www.boschrexroth.de/didactic.
3.5.2 Malfunctions due to contamination of
pressure fluid
3.5 General ancillary dangers and Contamination of the pressure fluid can be caused by:
protective measures when operating
Ø Wear during operation of the machine/system (metallic
hydraulic products
and non-metallic abrasion)
Ø Leaks of the hydraulic product
DANGER Ø Contaminants introduced during servicing/repair
In the interests of your safety, all safety instructions shall be Ø The use of dirty (unfiltered) pressure fluid when the pres-
carefully observed, especially those in the Operating Instruc- sure fluid is changed.
tions.
In spite of the high intrinsic safety of Rexroth hydraulic prod- Contaminants lead to malfunctions, increased wear and shorter
ucts, the risk of personal injury or damage to the environment service life of the hydraulic product. This can have negative
cannot be excluded, even when the equipment is properly effects on the safety and reliability of the hydraulic product.
used. Therefore the maintenance tasks specified in the Operating
New, additional dangers may arise if the hydraulic product is Instructions shall be carried out at regular intervals and the
installed in another machine or installed with other machines utmost cleanliness is required during work on the hydraulic
in a system. This shall apply in particular to mechanical move- product.
ments generated by the hydraulic product.
Information on these additional dangers can be found in the CAUTION
overall operating manual of the supplier of the overall system in
which the hydraulic product is installed. When changing the pressure fluid, always use factory-fresh
pressure fluid and filter it before filling to remove any contami-
nants in the pressure fluid that it often contains from the pack-
aging container (drum). Flush out lines and hoses before instal-
lation.
The cleanliness class of a pressure fluid is specified in accor-
dance with ISO 4406. Detailed information can be obtained
from the relevant datasheet or the Operating Instructions.
In older datasheets, the cleanliness class is sometimes speci- 3.5.4 Product-specific ancillary dangers
fied in accordance with NAS 1638. The following table can
be used to convert this to an equivalent ISO 4406 cleanliness All product-specific ancillary dangers and precautions can be
class: found in the relevant Operating Instructions.
Comparison table for cleanliness classes
Earlier class to Current class to 3.5.5 Disposal
NAS 1638 ISO 4406 (c)
Class 7 Class 18/16/13 Ø Take metal, cable and plastic ducts to a recycling materi-
Class 9 Class 20/18/15 als collection centre.
Ø Dispose of electronic components as electronic waste.
Ø Dispose of back-up batteries as special waste.
3.5.3 Electrical dangers
Ø Cleaning agents, operating fluids and other materials:
When working on electrical systems:
• De-energise the hydraulic system before beginning any CAUTION
maintenance work.
Please observe the disposal regulations specified in
• Cordon off the working area with red-white safety chain
the appropriate Safety Datasheets.
and warning signs.
• Lock the main switch, remove the key and keep it in a safe
place until the work is completed.
• Attach a warning sign to the main switch.
• Check that there is no voltage using a two-pole voltage
detector.
• Earth and short-circuit the point where you are working.
• Cover neighbouring live parts.
• Clear your workplace to prevent contact with live parts as
a result of tripping or slipping. Wear safety footwear.
• Always use electrically insulated tools.
• Disconnect plugs at sensors and valves – even those with
low voltages – after the system has been de-energised.
DANGER
Even after disconnection of the electrical supply
(main switch OFF) the following supply systems/danger
areas can still give rise to life-threatening voltages:
Ø Electrics, electronics, hydraulics (e.g. accumulators,
rechargeable batteries)
Ø Main switch
Ø Power supply cables
Ø Points identified with an electric shock warning sign.
4 Technical data and ambient conditions 4.2 Ambient conditions
IMPORTANT
4.2.1 Use in potentially explosive atmospheres
The product-specific technical data, operating limits and ambi-
ent conditions for the operation of your Rexroth hydraulic prod-
uct can be found in the Operating Instructions. DANGER
This includes the following information:
Rexroth hydraulic products shall be used in potentially
Ø Minimum flow rate for adequate cooling explosive atmospheres only if they are designed for this
Ø Permissible maximum temperature of the coolant purpose and this is expressly stated in the Operating
Instructions.
Ø Performance data
Ø Type of control and regulation functions IMPORTANT
Ø Permissible pressures, flow rates Directive 1999/92/EC of the European Parliament and Coun-
cil dated 16 December 1999 concerning the minimum require-
Ø Connections. ments for improving the safety and health protection of work-
ers potentially at risk from explosive atmospheres governs
protection from danger from potentially explosive atmospheres.
Observe the requirements contained in the regulations for
4.1 Information about pressure fluids operating equipment requiring supervision and the obligation to
produce explosion protection documentation.
Unless otherwise indicated in the Operating Instructions, the This involves, for example, dividing areas endangered by poten-
following specification applies to the pressure fluid to be used: tially explosive atmospheres into zones and specifying suitable
Ø Mineral-oil-based pressure fluid complying with the work equipment and procedures for these areas.
requirements of DIN 51524. Observe the requirements of Directive 94/9/EC of the Euro-
Ø Operating temperature range 0 °C…+80 °C pean Parliament and Council dated 23 March 1994 on the
(in tank < 72 °C). approximation of laws of the member states concerning equip-
ment and protective systems intended for use in potentially
Any deviations from this can be found in the Operating Instruc- explosive atmospheres (ATEX Product Directive) and/or the
tions. corresponding national legislation by means of which the Direc-
tive was implemented in law in the EU member states. The
IMPORTANT directive contains requirements for the use of equipment and
protective systems in potentially explosive atmospheres.
Bosch Rexroth recommends a maximum operating tempera-
ture of 55 °C, because the rate of ageing of the pressure fluid
increases and the service life of the seals and hoses is reduced
at higher temperatures.
Ø Viscosity ranges:
see RE 07075 and RE 90220
Ø Max. permissible contamination class of the pressure fluid
in accordance with ISO 4406: see 3.5.2 Malfunctions
due to contamination of pressure fluid.
The maximum permissible cleanliness class can be found in the
Operating Instructions. The following types of pressure fluids
shall be used.
IMPORTANT
Rexroth hydraulic components are tested with test oil MZ45
manufactured by ESSO (class ISO VG 46 at 40 °C),
(Viscosity η = approx. 46 mm2/s).
4.2.2 Climatic operating conditions
Unless otherwise indicated in the Operating Instructions,

the permissible ambient temperature
Ø for control units: 0 °C…+50 °C
Ø for drive units with electric motors without heat exchang-
ers, surface-cooled by free air circulation:
0 °C…+30 °C
Ø for drive units with heat exchangers: < +40 °C.
Unless otherwise specified, Rexroth hydraulic products are

designed for use in temperate climate zones and in covered
areas (not in the open air) at relative air humidities of < 70 %
and at room temperatures of 22 °C.
IMPORTANT
For systems with oil-air heat exchangers:
Observe the information given in the circuit diagram in the
Operating Instructions.
In relation to the electronic equipment, the permissible ambient

conditions apply to installed and protected electrical connec-
tions of class IP 55.
Ø Ambient temperature +5 °C…+40 °C
assuming that the average air temperature over a 24 hour
period does not exceed +35 °C.
Ø Relative air humidity: 23…95 %, non-condensing.
Ø Altitude: up to 1000 m above national datum.
DANGER
Rexroth hydraulic products shall not be used in aeronau-
tical equipment, except where they have been specially
approved and appropriately labelled to this effect.
5 What you need to know about IMPORTANT

pressure fluids Observe the following rules of thumb:
At pressure fluid temperatures >70 °C, the rate of ageing dou-
bles for each 10 °C.
5.1 How to handle pressure fluids safely
5.3 Viscosity
DANGER
Mineral-oil-based pressure fluid is hazardous to water and
5.3.1 Viscosity grades
flammable.
It may only be used if the relevant safety datasheet from The most important characteristic of a pressure fluid is its vis-
the manufacturer is present and all the measures stipu- cosity, i.e. stickiness. Viscosity range always plays a priority
lated therein have been implemented. role in the selection of a pressure fluid.
Viscosity is measured in the SI unit [mm2/s]. Many manufactur-
ers still provide their information in centiStoke [cSt], the equiv-
alent of [mm2/s].
5.2 Functions and effectiveness The viscosity grades (VG = viscosity grade) in accordance with
ISO 3448 relate to the viscosity at 40 °C. The viscosity grade
Due to the many tasks of pressure fluid, its selection, inspec- is appended to the type designation or the commercial name of
tion and maintenance are of vital importance for: the pressure fluid.
Ø proper functioning Example: A pressure fluid with a viscosity grade of ISO VG 46
has a viscosity of 46 mm2/s at 40 °C.
Ø operating safety
The relationship between medium temperature and viscosity for
Ø service life hydraulic oil (example)
Ø and the cost effectiveness of the hydraulic product.
Medium
Viscosity
temperature
The tasks of pressure fluid: 3 °C 800 mm2/s
Ø to transmit hydraulic energy from the pump to the hydrau- 8 °C 500 mm2/s
lic cylinder/motor 25 °C 100 mm2/s
60 °C 20 mm2/s
Ø to lubricate parts moving against one another
77 °C 12 mm2/s
Ø corrosion protection
Ø to remove contaminants Too high a viscosity leads to the formation of air and vapour
bubbles as a result of low pressure (cavitation). Too low a vis-
Ø to remove locally accumulated heat. cosity leads to increased leakage losses. Increased leakage
losses cause the pressure fluid to heat up more, leading in turn
to a further reduction in viscosity. The pressure fluid then loses
its ability to lubricate.
5.2.1 Reduced function due to ageing
Valves, pumps and hydraulic motors, in particular, require exact
The effectiveness of pressure fluid diminishes as it ages compliance with the defined viscosity ranges.
(undergoes chemical changes). Acids and resinous residues
For certain ambient and operating temperatures, not all the
form, which may cause valve spools to stick.
requirements can always be covered with the available ranges
The following factors accelerate the ageing process: of the viscosity grades.
Ø high temperatures In order to comply with all the requirements, high viscosity
pressure fluids with viscosity index improvers or a pressure
Ø oxygen in the pressure fluid fluid cooler/heater may be used.
Ø air humidity
Ø water
Ø metallic catalysers
Ø operating pressure
Ø contaminants.
5.4 Leakage fluid
Clearances and play mean that some leakage fluid escapes

from all hydraulic products. Leakage fluid can be lead away
internally or externally, depending on the component. It can be
fed back into the tank or must be disposed of.
CAUTION
Make sure that the leakage fluid is fed back into the tank
in a proper manner.
Dispose of leakage fluid that is not fed back into the tank
properly, in compliance with the applicable environmental
protection regulations.
5.5 Topping up/refilling
CAUTION
When topping up/refilling your hydraulic system, make
sure that you use pressure fluid of the same sort and type
and from the same manufacturer.
If the fluid is heavily contaminated or prematurely aged,
then the system, including the tank must be cleaned and
flushed before refilling. New pressure fluid must always be
filtered in accordance with the required cleanliness class,
as it does not normally meet the required cleanliness class
in the as-supplied state.
6 Construction and mode of operation

of a hydraulic system 9

Hydraulics (fluid technology)
7
Transmission, control and distribution of energy and signals
using a pressurised fluid medium. 6
Hydraulic system 5
Arrangement of interconnected components for transferring
and controlling hydraulic energy.
4
3
Component
2
A single unit (e.g. a valve, filter, cylinder, motor) that consists
of one or more parts and which is a functional constituent of a 1
hydraulic system.
1 Tank
Oil preparation
2 Filter
Drive
3 Pump Energy conversion
A component that converts the energy of the hydraulic fluid
into mechanical energy (e.g. motor, cylinder). 4 Pressure limiting valve
5 Directional valve
Energy control
6 Check valve
6.2 Schematic 7 Throttle valve
8 Hydraulic cylinder
In a system operated with hydraulic oil, first of all mechani- Energy conversion
cal energy is converted into hydraulic energy, transported and 9 Hydraulic motor
controlled in this form, to finally be converted once more into
mechanical work.
The hydraulic elements are arranged in accordance with these 6.3 Safety concept
functions. The following diagram shows a schematic represen-
tation of the elements of a complete hydraulic system. Hydraulic products contain sensors and actuators, the interac-
tion of which is particularly important with regard to the fulfil-
To demonstrate their operating principle, standardised symbols
ment of technical safety functions.
(ISO 1219) are used instead of sectional diagrams of the vari-
ous devices. Line connections are represented by simple lines, Individual hydraulic products form part of an overall safety con-
as can be seen in the example. cept.
Applications required to perform safety functions are designed
using special hydraulic components that satisfy the require-
ments of the relevant directives, such as the Pressure Equip-
ment Directive and other standards.
The manufacturer of the overall machine or system defines and
bears responsibility for the safety category to EN 954-1 to be
fulfilled.
IMPORTANT
A more detailed description of the safety concept and the spe-
cific safety components installed can be found in the Operating
Instructions and the Operating Instructions of the supplier of
the overall system in which the hydraulic product is installed.
7 Moving hydraulic units/components IMPORTANT

The factory-applied corrosion protection is adequate provided
Hydraulic units or components may be moved by a fork-lift that
truck or a hoist, depending on their size and the local condi-
tions. Ø no condensation or leakage water can enter the system
Ø long standstills are avoided.
IMPORTANT
Contact Bosch Rexroth if you are not clear about the conse-
For details see the Operating Instructions.
quences of long standstills on the state of the hydraulic prod-
uct.
CAUTION
Always ensure hydraulic products are empty of pressure 8.1.2 Storage times in relation to the ambient
fluid for transportation. conditions
Rexroth hydraulic products are delivered empty of pressure
fluid. However, products may contain oil residues left over from Delays in bringing into use, long shipping and storage times or
the final inspection at our factory. long periods of non-use can lead to rust formation in Rexroth
hydraulic products. Additional corrosion protection measures
must be implemented to prevent this.
IMPORTANT
8 Storage and longer standstills If all the openings on the hydraulic products are not sealed so
as to be air-tight, this will reduce the storage life of the hydrau-
lic product by nine months.
8.1 Hydraulic systems - subsequent bringing After the specified storage time has expired, in any event not
longer than 24 months, the corrosion protection must be
into use after storage
checked and further conservation measures applied if neces-
sary.
Corrosion, especially oxidation, can cause metal surfaces to
lose the standard of surface finish required for the hydraulic
system to function properly.
Rust and other metallic and non-metallic particles lead to abra-
sive wear (erosion), which detrimentally affects the functioning
of the hydraulic system.
CAUTION
If a hydraulic system is to be brought into use again fol-
lowing a long standstill, it must first be flushed clean.
8.1.1 Factory-applied corrosion protection
Rexroth hydraulic products are tested in accordance with

Class III using a hydraulic oil that has additional anti-corrosive
properties. The film of oil that remains in the product after the
test provides sufficient internal corrosion protection.
This factory lubrication ensures that valves do not stick during
subsequent use of the hydraulic product, and guarantees com-
patibility with seals and the pressure fluid to be used.
8.2 Seals, hoses and hose lines
CAUTION
Seals:
Observe the requirements of ISO 2230 and/or DIN 7716
and the specific manufacturer’s data on seals.
Hoses and hose lines:
In the Federal Republic of Germany, please observe the
requirements of DIN 20066, ZH 1/74 Safety rules for
hydraulic hose lines and the specific manufacturer’s data
on hoses and hose lines.
In addition, the following conditions shall be observed:
Ø Seals, hoses and hose lines are stored in cool, dry and
dust-free conditions.
The hoses and hose lines can be enclosed in plastic foil to
ensure low-dust storage conditions. Ideal storage conditions
for hoses and hose lines are temperatures from +15 °C to
+25 °C and a relative humidity of below 65 %.
Ø Do not store elastomers below –10 °C. The ideal stor-
age conditions for seals are temperatures from +10 °C
to +20 °C and a relative humidity of between 65 % and
75 %.
Ø Store hoses and hose lines in the original packaging if
possible. Prevent the entry of air.
Ø Avoid direct sunlight and UV radiation and shield from
nearby sources of heat.
Ø Darkened storage locations are preferred.
Ø Do not use ozone-forming light sources or equipment
(e.g. fluorescent lamps, mercury-vapour lamps, copiers,
laser printers) or electrical spark-forming devices in the
vicinity of hoses and hose lines.
Ø Seals, hoses and hose lines must not come into contact
in particular with materials or vapours that could damage
them (e.g. acids, alkalis, solvents).
Ø Store seals, hoses and hose lines lying down and free
from tension. If the hoses and hose lines are coiled, take
care not to bend them to less than the smallest bending
radius specified by the manufacturer.
Maximum storage times
Ø NBR seals: 4 years
Ø FKM seals: 10 years
Ø Hoses: 4 years
Ø Hose lines: 2 years
For reasons of safety, seals, hoses/hose lines shall not be

used once these permissible storage times are reached or
exceeded. Permissible storage times could be considerably
reduced if the permissible storage conditions are not main-
tained. If you are not clear about the storage times and/or stor-
age conditions then you should not use the product.
9 Assembly and bringing into first use Bringing into (first) use shall only be done by an instructed,
authorised hydraulics expert who has the required special-
ist knowledge.
IMPORTANT
Specialist hydraulics knowledge means, among other things,
Only the permissible pressure fluids given in the Operating that the person can read and fully understand hydraulics draw-
Instructions are to be used. Information on other pressure flu- ings. In particular, he must fully comprehend the range of func-
ids can be found in the Operating Instructions or are available tions of the integrated safety components as part of the overall
on request. safety concept.
Filling the pressure fluid tank must always take place through a
suitable filter unit. Experience has shown that even new pres-
sure fluid can often have more than the maximum permissible
level of contamination. 9.2 Before bringing into first use
All information specific to assembly and bringing into first use
can be found in the Operating Instructions. 1. Check the scope of delivery for transport damage.
Pay attention to cleanliness: 2. Check that the Operating Instructions for the Rexroth
hydraulic product are present and complete.
Ø Do not use cleaning wool or cloths containing fibres for Contact us if the Operating Instructions are not there or
cleaning. are incomplete.
Depending on the condition of the system or machine, 3. Assemble the hydraulic product.
cleaning with fibre-free cloths may be sufficient. Use suit-
able liquid cleaning agents to remove lubricants and other • Observe the Operating Instructions and this product
stronger contaminants. Make sure that cleaning agent information.
does not get into the hydraulic system. • Assemble the hydraulic components, so that they are
Ø Never use hemp and putty as sealants. mounted strain-free on even surfaces.
• Tighten the fastening bolts evenly using the specified
The functional or failure behaviour of identical hydraulic prod- tightening torque.
ucts may vary due to conditions specific to the machine or sys- 4. Ensure that the interfaces of the system/machine and the
tem in which the hydraulic product is installed (mass, speed, installation conditions provide for safe operation of the
electrical triggering at setpoint values, etc.), see also Section hydraulic product. If in doubt, consult the people responsi-
11 Trouble-shooting. ble for the overall system/functional machine.
5. Check the construction of the hydraulic product against
the circuit diagrams, lists of equipment and assem-
bly drawings. If there are any differences, draw this to
9.1 Safety advice for assembly and the attention of the people responsible. If important
bringing into first use documents are missing, they can be requested from
Bosch Rexroth. Only documents issued by the bodies
authorised to do so shall be used.
DANGER 6. Based on the Operating Instructions for the system or
machine in which the hydraulic product is installed, check
Hydraulic products are generally intended for installation whether bringing the hydraulic system into use could lead
in machines/systems or devices. to uncontrolled, dangerous movements. Where appropri-
The function of the hydraulic product must therefore ate, take into account the hazard analysis/risk assessment
always be seen in relation to the function of this machine for the system or machine.
– i.e. seemingly identical hydraulic products may demon- 7. Take the precautions appropriate to the anticipated dan-
strate different functional behaviours as a result of the gers, e.g.
function of the machine in which they are installed.
• Ensure that the cylinder piston rod can move out with-
For this reason, a hydraulic drive must not be brought into out danger.
use until it has been determined that the machine in which
it is installed conforms to EU standards. • Use a hoist or other lifting device to additionally
secure lifted loads.
Do not bring hydraulic drives into use until you have famil-
iarised yourself completely, firstly with the function of the
hydraulic product and hydraulic equipment and secondly
with the hydraulically powered machine functions, and
have clarified and dealt with any possible dangers.
8. As part of bringing into (first) use, check whether the elec- 9.3 Bringing into first use,
tric motors and valve solenoids can be switched manually subsequent bringing into use
using the electrical controls of the system/machine. If they
cannot be switched manually – or can but with difficulty
– you must provide a remote control (e.g. test boxes for
Rexroth proportional valves) for the internal function test of DANGER
the hydraulic system.
Before bringing into (first) use, have all pressure accumu-
IMPORTANT lators and safety systems checked by an expert or special-
ist in accordance with national regulations.
Starting up the hydraulics solely by means of emergency man-
ual operation is not recommended, as several valves at once 1. Clean the lock on the transport and storage container
cannot be switched as required in the correct sequence. before opening.
9. Draw up a sequential program for bringing into (first) use 2. Clean the hydraulic unit and all other component groups,
and store it with the technical documentation as an appen- so that no dirt can get into the hydraulic system during
dix to the Operating Instructions. bringing into (first) use.
For this you should consider the following: 3. Check the paint on the tank for integrity.
Hydraulic drives basically consist of the following func-
tional groups 4. Flush the connection lines to remove dirt, scale, chips etc.
Ø Pump circuit (generation of pressurised oil flow); 5. Pickle and flush welded pipes.
pump, electric motor, oil tank, filters, monitoring
devices, etc.
CAUTION
Ø Control system for at least one hydraulic consumer
(cylinder, motor); directional control valves, pressure Remove all residues of water and cleaning agents
and flow control valves, check valves before performing further work.
Ø Hydraulic consumers (cylinders, motors) with spe-
cially assigned valves, e.g. braking valve.
6. Clean the interior of the hydraulic components to get rid of
contaminants:
10. Divide the functional circuit diagram into separate mini-cir-
cuits that can each be started up in succession. • Clean the filler plug of the pressure fluid tank.
11. Read the functional circuit diagram and seek clarification • Remove dust and chips using an industrial vacuum
of any unclear text or diagrams. More information about cleaner, by rinsing parts or similar cleaning method.
the functioning of components, e.g. a pump regulator, is • Completely remove any oil residues left over from the
available in the Technical Datasheet. factory test.
12. Establish into which position valves are to be switched, or • Remove any gummed oil which may have formed due
how valves are to be set. to incorrect storage.
13. Put up any necessary directional, prohibitive or informative
signs and check whether the meaning of these signs are 7. Connect up all connection lines.
explained in the Operating Instructions.
14. Follow this sequence for bringing into (first) use IMPORTANT
Ø Pump circuit Observe the installation instructions from the manufacturer
of the connection components.
Ø Parts of control system:
e.g. pressure cut-off and switchover,
open centre, DANGER
pressure reduction etc.
Make sure that pipes and hoses are connected at all
Ø Cylinder and motor circuits:
ports or that the ports are sealed with screw plugs.
First move,
fill and bleed, 8. Carry out a special check to make sure that the union nuts
then finally optimise all settings. and flanges are correctly tightened at the pipe connec-
tions and flanges.
IMPORTANT
CAUTION
Mark all the checked connections, e.g. with paint.
Make sure that all pipes and hoses and every combination of Use oil filler units (filter units) suitable for pres-
connection pieces, couplings or connection points with hoses sure fluids.
or pipes are checked for their operational safety by someone • Do not remove the filter strainers from filler necks or the fil-
who has the appropriate knowledge and experience. ter element from filters before filling the pressure fluid tank.
13. Fill the pressure fluid tank up to the upper mark on the
9. Connect the hydraulic consumers. Dimension the connec- inspection window. Observe the maximum fluid level, tak-
tion lines in accordance with the performance data in the ing into consideration the volume in the connection lines
Circuit Diagram and the Operating Instructions. and hydraulic consumers.
10. Install the electrical system for the drive and control sys- 14. Set the pressure and flow control valves, pump regula-
tem: tor, signalling elements such as pressure switches, limit
• Check the connected loads. switches and temperature regulators to the settings and
values defined in the sequential program (see 9.2 Before
• Connect coolant water if necessary. bringing into first use).
• Check the direction of rotation of the pumps
(e.g. as indicated by attached arrow markings). DANGER
11. Check the pressure fluid to ensure that no water has Do not change the settings of valves with a safety
entered it. function, valves with a position switch or valves with
preset electronics.
12. Before filling the pressure fluid tank, please observe the
following requirements: • Set operating-pressure valves and flow control valves
to the lowest possible values.
Ø The pressure fluid must conform to the specification
in the Operating Instructions. • Set directional control valves to their basic setting.
• Reduce the setpoint values of proportional valves to
CAUTION minimum values.
• Do not remove the tamperproof lead seals. Damaged
Never fill new hydraulic products with used pressure or removed tamperproof lead seals indicate improper
fluid. use of the hydraulic product.
Ø The drums of pressure fluid must be sealed and clean 15. If applicable:
on the outside. Fill the pressure accumulator to the specified gas pre-
charge pressure and then check the pressure, see Operat-
ing Instructions.
IMPORTANT 16. Fill the pump body:
If the pressure fluid has a high level of initial contamination Use the leakage oil port to fill pump bodies that have this
(see 4 Technical data and ambient conditions): feature, see Operating Instructions.
Use a filter unit to fill the pressure fluid tank. Ensure that the fil- 17. If applicable:
ter element is clean. Open the cocks in the suction line.
18. Start the drive motors:
IMPORTANT
• With electric motor in jogging mode, allow to start
The fineness of the filter shall correspond to the cleanliness
briefly
class required by the overall system and if possible be even
finer. • Combustion engines in idle
The filter unit used shall fulfil the requirements for functional
• Pay attention to the direction of rotation.
safety and service life.
• If possible, fill the pressure fluid tank via a filling coupling,
using a return filter if possible.
19. Bleed the hydraulics (valve, pump, motor, line, cylinder). 23. After bringing the machine into first use, have a sample of
the pressure fluid analysed to ensure that it achieves the
IMPORTANT required cleanliness class. Change the pressure fluid if the
required cleanliness class is not achieved.
Details on bleeding can be found in the Operating Instruc- If the pressure fluid is not tested in the laboratory after
tions. bringing the machine into first use:
• Operate the hydraulic product at low pressure until it Change the pressure fluid.
is fully bled. 24. Replace the pressure fluid filter.
• Bleed the hydraulics lines to consumers or measuring 25. Document and file all set values.
points at the highest point, if possible.
• Operate the directional valves in jogging mode.
• Next, advance and retract all hydraulic consumers DANGER
several times.
26. To ensure the safety of persons and the system, after
• Increase the load slowly. Check the pressure fluid
bringing the machine into first use, perform the following
level in the pressure fluid tank. If necessary, top it up
tests using the defined maximum values:
with pressure fluid.
• Function test
Bleeding has been accomplished fully and correctly if the pres- • Pressure test.
sure fluid in the tank does not foam, if the hydraulic consumers
do not make any jerky movements and if no abnormal noises Prepare a record of the bringing into (first) use or accep-
can be heard. tance and have it signed by the plant operator. This record
is an important document and requires to be filed.
20. Set the valves and sensors and start up the machine:
• Set the switching operations of valves with a switch- IMPORTANT
ing time adjustment/ramp in accordance with the Information on how to perform the function test and pres-
dynamic conditions, see Operating Instructions. sure test can be found in the Operating Instructions.
• Finely adjust and optimise the setting of proportional
valves without on-board electronics (OBE).
Manufacturing tolerances mean that valves and amplifiers have

to be adjusted in line with one another. Valves with in-built elec-
tronics (OBE, On Board Electronics) have the valve and ampli-
fiers adjusted in line with one another at the factory.
Amplifiers for valves without OBE are supplied from the fac-
tory with a basic setting. Depending on the type of valve and
amplifier, you may have to fine-tune the null point and sensitivity
before bringing the valve into use.
IMPORTANT
Details on fine-tuning can be found in the Operating Instruc-
tions.
21. Check the operating temperature after the machine has
been running continuously for several hours. Too high an
operating temperature indicates that there are faults that
need to be analysed and rectified.
22. Rectify any leakages, e.g. by relieving couplings from pres-
sure and then retightening.
IMPORTANT
Apart from moisture, which should not be sufficient to form one
drop, no measurable, unintentional leakage shall be found.
10 Operation Ø Is there a machine record book that may document similar

malfunctions in the past?
IMPORTANT
Please refer to the Operating Instructions for all information on 11.2.2 Recommended way of working when
how to operate the Rexroth hydraulic product.
trouble-shooting
Successful trouble-shooting for a hydraulic product requires

precise knowledge about the structure and method of opera-
11 Trouble-shooting tion of the individual components.
Where hydraulics are combined with electrics/electronics, in
particular, trouble-shooting is rendered more difficult and co-
operation between electricians and hydraulic specialists is
11.1 What to do in the event of a fault required.
• Even if you are under time pressure, proceed systemati-
cally and methodically.
DANGER Indiscriminate, hasty dismantling and readjustments may,
in the worst case, result in the original cause of failure
In the event of abnormal occurrences or malfunctions, stop being impossible to determine.
all work on the Rexroth hydraulic product immediately and
inform the responsible personnel. • Make sure that you gain an overview of the function of the
hydraulics in respect of the overall system in which the
IMPORTANT hydraulics are installed.
A table for product-specific trouble-shooting can be found in • Try to find out whether the hydraulics performed the
the Operating Instructions. required function in the overall system prior to the occur-
rence of the fault.
If the responsible personnel are unable to rectify the problem
immediately: • Try to determine any modifications to the overall system in
which the hydraulics are installed:
• Switch off the main switch. If applicable, turn off any com-
bustion engines used as drive motors. Ø Have the operating conditions or operating range of
the hydraulics been changed?
• Secure the main switch against being unintentionally
switched on again. Ø Have modifications (e.g. retrofitted equipment)
or repairs been carried out on the overall system
• Inform the machine manufacturer. (machine/system, electrics, control system) or on the
hydraulics? If yes: What were they?
Ø Have the set values of the hydraulics been changed?
11.2 The basic approach to trouble-shooting Ø Have the hydraulics recently undergone mainte-
nance?
The information in this section is intended to help you create
the ideal conditions for carrying out trouble-shooting as effi- Ø Has the hydraulic product/machine been operated
ciently as possible. improperly?
Ø How does the malfunction manifest itself?
11.2.1 General conditions • Form a clear picture of the cause of the fault. Ask the
machine operators directly, if necessary.
Ø Is all the necessary technical documentation to hand? • Document any work undertaken, changed set values, etc.
Ø If no hydraulic circuit diagram is available: • Document any amendments/additional information that
Can a hydraulic circuit diagram be drawn using the struc- should be included in the Operating Instructions.
ture, signs and labelling of the equipment?
Ø Are there enough measuring points?
Ø Has the customer provided useful information about how
the malfunction manifests itself and about the functional
behaviour of the system/component prior to the malfunc-
tion?
11.2.3 Systematic trouble-shooting procedure 11.3 Trouble-shooting tables
Ø Is there an inspection and maintenance book which might

provide information about the trend of test parameters IMPORTANT
(e.g. temperature of hydraulic fluid, replacement intervals The causes of failure in hydraulic systems can be extremely
of filter elements, noises)? complex. Therefore, general rules for trouble-shooting can only
Ø Have there been any identical or similar failures in the be laid down to a limited degree.
past? Please refer to the relevant Operating Instructions for product
• Make a note of causes of failures with a low probabil- specific information about trouble-shooting the Rexroth hydrau-
ity. Only investigate the failure causes you have noted lic product.
down if all failure causes with a high probability have
been proven to be inapplicable.
• Draw up a list of priorities of the most probable failure
causes.
• Verify these listed failure causes one after the other
(by means of theoretical conclusions, disassembly,
measurements or tests).
• Document the causes of failure you have discovered,
and note down how you discovered them.
12 Maintenance Before undertaking any manual intervention in the Rexroth

hydraulic product:
12.1 Definitions of terms DANGER

The term Maintenance as defined in DIN 31051 encompasses Please refer to the Operating Instructions for all the neces-
all measures to maintain and restore the desired conditions sary information on depressurisation and on those parts of
and to determine and assess the actual condition of the techni- the Rexroth hydraulic product that are not depressurised
cal devices of a system . automatically.
These measures are divided into the following categories: • Advance all cylinders to their safe end position.
Ø Inspection (determining the actual condition) • Lower all loads.
Ø Servicing (maintaining the desired condition) • Switch off all pumps.
Ø Repair (restoring the desired condition). • Mechanically support vertical cylinders so that they
cannot drop. Never perform any maintenance work on
The above measures include:
raised units without external support.
Ø Adapting maintenance objectives to suit company objec-
• Relieve any accumulators of pressure in the proper
tives
manner.
Ø Determining appropriate maintenance strategies.
• Switch off the pressure supply and secure the hydrau-
lic product against being inadvertently switched on
again.
12.2 Safety during maintenance tasks • Ensure that only authorised personnel remain in the
work zone.
• Wear safety glasses, gloves and boots.
DANGER
• Allow pressure lines and sections of the system which
In the interests of safety, please observe all the following have to be opened to cool down before commencing
safety instructions carefully and at all times. maintenance work.
• Check safety devices regularly to see that they are work- • Open with care any segments that have to remain
ing properly. under pressure.
• Perform all maintenance work properly, completely and

within the stipulated periods and make a record of the Since check valves are located in the pressure lines above the
work. pumps, the hydraulic system may still be under pressure even
after it has been disconnected from the actual pressure supply.
• Inform all personnel before commencing maintenance
work. Certain segments, such as servo cylinders, also continue to
remain under pressure because the proportional valves remain
• Generously cordon off the maintenance zone before com- in the closed position (all valves are illustrated in their basic
mencing work. position in the hydraulics diagram).
• Inform all persons of ongoing maintenance work by means Observe the following:
of the appropriate signs.
In particular, attach warning signs to the control cabinet, Ø Only new, interchangeable and tested components,
main switch, actuators and points of access. replacement parts and lubricants in original-equipment
quality are approved for use/replacement.
If you have to switch off the hydraulic product, secure it against
being unintentionally switched on again as follows: Ø For reasons of safety, the installation of used and/or
untested components is strictly prohibited and leads to
• Switch off all drives, disconnect the hydraulics from the loss of EU Conformity.
mains at the main switch.
• Depressurise the hydraulic product (relieve any pressure Exercise extreme vigilance when operating the hydraulic prod-
accumulators of pressure). uct in maintenance mode, which may in certain circumstances
• Secure the main switch against being unintentionally necessitate the temporary removal of certain safety devices.
switched on again.
Make sure that all safety devices are properly installed and • Document and file details of any work undertaken,
have undergone a function test before bringing the system changed set values, etc.
(back) into use.
• Document and file details of any amendments/additional
• Perform welding, burning or grinding work on the hydrau- information that should be included in the Operating
lic unit or its attachments only with the approval of local Instructions.
safety authorities/fire brigade and with suitable protective
• Modifications and additions could affect the validity of the
covering to prevent ingress of contaminants.
EU Conformity Declaration/Manufacturer’s Declaration.
• When performing assembly work above your height, use Always consult Bosch Rexroth about any proposed modifi-
the steps and platforms provided by the plant operator. Do cations or additions.
not climb on any parts of the system.
• Remove all tools and materials needed for maintenance
from the hydraulic product.
• Always rectify any leakage from the hydraulic product
immediately.
• Always inform personnel before (re)starting the hydraulic
product.
12.3 Inspection and servicing
The objective of inspection and servicing is

Ø To maintain all system functions along with the initial
parameters of the system
Ø To ensure continual availability of the system
Ø To detect weak points
Ø To ensure that the system attains the required service life.
IMPORTANT
The following general specifications are based on use of the
hydraulic product in central Europe and under the usual operat-
ing conditions of commercial and industrial plants.
We strongly recommend the use of an inspection and servicing
book, in which all work specific to that site, and all inspection
and servicing intervals should be defined and documented.
An inspection and servicing book is also helpful in that
Ø It provides comparison values to aid with early detection of
malfunctions
Ø It allows warranty claims to be dealt with more easily.
CAUTION
Ensure cleanliness during all work.
• Please observe the requirements for pressure fluids men-
tioned in Section 9 Assembly and bringing into first use.
• Clean the external environment of couplings/joints and
devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
• Seal all openings using protective caps.
• Bleed the hydraulic product after each item of servicing
work.
12.3.1 Inspection procedures and test equipment, 12.3.2 Location of testing and measuring points
general
IMPORTANT
The following are some of the typical inspection and testing
procedures that are regularly used in connection with hydraulic Please refer to the Operating Instructions for the installation
systems and components. location of filling level indicators, filling points, drainage points,
filters, testing points, strainers, solenoids, etc. that require reg-
IMPORTANT ular inspection and servicing.
Keep the indicated typical test equipment ready for this type of
work.
12.3.3 Inspection and servicing plan, hydraulic
Type of test Typical test Typical products, general
equipment testing activities
The graph illustrates the concept of wear/wear margin.
Pressure Pressure gauge Checking of The wear margin is a characteristic feature used to describe
measure- or sensor with the condition of the system for the purpose of maintenance.
• specified pressure
ment suitable measuring
range and connec- • opening pressure 5
tion pipe and con-
• pressure difference
nection coupling
before and after the ��
object under test ��
Visual – Checks for

inspection
• all components
securely seated 1
• damage
4
• wear 6
• leakage (formation of �
oil droplets) ��
• presence of all 2
3
warning and
informative signs 1 Wear margin Z0
2 Time t
Touch – Checks for
inspection 3 Repair (corrective maintenance) time (ti2 – ti1)
• unusual local
vibrations 4 Damage threshold (damage time tS)
5 Desired condition after corrective maintenance
Temperature Temperature Checks for 6 Failure
inspection measuring
• unusual local
instrument
temperature zones
The reduction in the wear margin reflects wear. The curve rep-
resents one possible form of the wear profile during the period
Acoustic – Checks for
of use. It is determined during inspection and varies depend-
inspection
• changes in running ing, firstly, on the system itself (e.g. material selection, sur-
noise of the unit face treatment, quality) and secondly on external influences
or boundary conditions such as servicing levels, corrosive cir-
• changes in flow culating air and dust. Thirdly, it depends on how the system
noise is operated; whether with partial load or partially with excess
• changes in operating load, whether it is subject to surge loads or steady load, etc.
noise in the unit and Where hydraulic systems are concerned, the curve is also influ-
valve control. enced by the cleanliness class and degree of fouling of the
pressure fluid, the number of cycles and the ambient condi-
tions.
All the factors mentioned above can exert an influence on the 12.3.5 Inspection and servicing plan: electrics and
curve but this need not necessarily adversely affect the quality control system
of its information, as wear always signifies the reduction in the
wear margin, which is understood to be the primary initial vari-
able before wear commences. IMPORTANT
Consequently, this means that a sudden change in the wear The product-specific inspection and servicing plan for electrics
margin must also count as wear, and that the element of time and control systems can be found in the Operating Instruc-
on its own is not of decisive importance for wear, but is of con- tions.
siderable interest in the assessment and evaluation of such
wear.
An increase in the wear margin to over 100 % above its base-
line may be achieved through corrective maintenance, if such 12.3.6 Lubrication points, lubricants, intervals
measures entail an improvement and this increase is estab-
lished as the new desired condition for future corrective main- IMPORTANT
tenance.
The details of the specified lubricants, lubrication points and
Certain system parts may be subject to a wear margin which associated lubrication cycles can be found in the Operating
diminishes in such a way that the time available for use is insuf- Instructions.
ficient for the requirements of the plant or operation. In this
case, investigations must be carried out to ascertain whether
the introduction of suitable technical measures might counter
this reduction in the wear margin to a satisfactory extent. The
time and expenditure required for such measures must natu-
12.3.7 Set values of valves, regulators and
rally be kept in reasonable proportion to the expected degree signalling elements
of success.
Pressure and flow control valves, pump regulators and signal-
If such conditions arise, we refer to these parts as weak points. ling elements such as pressure sensors, pressure switches,
Since their elimination may provide economic and safety limit switches and temperature regulators are given their opti-
advantages, weak points require to be rectified immediately. mum setting when the system is brought into first use.
IMPORTANT Check regularly whether all values are correctly set with the aid
of the hydraulics diagram and the documented values.
The inspection and servicing plan for your particular product
can be found in the Operating Instructions.
DANGER
The set values of valves with position switches shall only
12.3.4 Inspection and servicing plan, be calibrated or readjusted at the factory.
electrohydraulic systems The set values of safety valves shall not be altered by the
user. Any readjustment shall be performed by authorised
Electrohydraulic systems with proportional valves must be ser- testing bodies only.
viced in accordance with hydraulic requirements and strate-
Too low a pressure difference between the operating pres-
gies. However, technical control components must also be
sure and the opening pressure can lead to frequent opening
incorporated in these servicing cycles.
of safety valves. This leads to increased power losses and an
On this basis, an overall strategy for system servicing must be unacceptable increase in temperature of the pressure fluid. In
developed and documented. this event, select a lower operating pressure.
IMPORTANT
The appropriate component characteristics relevant to servic-
ing can be found in the Operating Instructions.
12.3.8 Replacement of pressure fluid filters and

ventilation filters CAUTION
In certain circumstances the contamination indicator does
not show a required filter replacement.
CAUTION
If the check function never indicates filter replacement and the
Unfiltered pressure fluid filters lead to increased wear of contamination indicator is functioning correctly, this may have
all the system’s hydraulic products and can cause func- the following causes:
tional failures with dangerous effects. Therefore, always Ø Faulty filter
replace contaminated oil filters immediately.
Ø A bypass valve may have been installed and is not closing
Clogged ventilation filters result in inadequate cooling and correctly, e.g. due to the entry of dirt particles.
can therefore cause excessive heating up and malfunc-
tions of the hydraulic system. Therefore, always replace
contaminated ventilation filters immediately.
• Clogged filters must always be replaced immediately. 12.4 Service and storage lives of hose lines
Do not clean clogged filters.
• Allow the contents of the replaced oil filter to drip and ful- IMPORTANT
ly drain. In terms of the service life of hydraulic hose lines in these
• Dispose of the filter in accordance with the applicable reg- Operating Instructions, replacement and storage lives are mea-
ulations. sured from the date of manufacture of the hose line.
Even when properly stored and subjected to permissible loads,
Exact instructions on how to replace a filter can be found in the seals, hoses and hose lines undergo a natural ageing process.
Filter manufacturer’s instructions for use. The replacement and storage lives of seals, hoses and hose
lines are therefore limited (see 8.2 Seals, hoses and hose
lines).
12.3.9 Checking filters with a contamination indicator

DANGER
Filters with contamination indicators continuously measure the
degree of fouling. The dirt-retention capacity of the filter is uti- Hose lines must be replaced in accordance with the provi-
lized to the full. sions of the servicing plan, even if there are no detectable
technical defects in the hose line.
IMPORTANT Hoses that have already been used as part of a hose line
Check the contamination indicator when the pressure fluid is shall not be reused in a hose line.
warm (during or immediately after operation).
The first use may have changed the properties of the hose
If the ambient temperature is low or the pressure fluid is cold, material to such an extent that reuse of the hose repre-
its high viscosity may cause clogging to be indicated, although sents a very high risk.
the pressure fluid is in fact clean.
Procedure:
1. Wait until the hydraulic product has reached operating
temperature.
2. Press the indicator button (check function):
If the indicator button pops out again immediately, the filter
must be replaced by the end of the shift at the latest.
Due to the progressive loss in pressure as the filter becomes

increasingly contaminated, the indicator point has a certain
reserve capacity, i.e. generally sufficient for a work shift of 8 h.
If the filter is not replaced after 8 h, dirt may penetrate the sys-
tem, resulting in contamination of the hydraulic product.
12.5 Topping up the pressure fluid 12.7 Repair
IMPORTANT IMPORTANT
Only pressure fluids specified in the Operating Instructions are Repair (corrective maintenance) is the restoring of the desired
to be used. condition.
When changing or topping up the pressure fluid, fill the pres- In addition, observe the special safety instructions in
sure fluid tank on the hydraulic product as follows: 12 Maintenance and the safety instructions in the Operating
Instructions.
1. Fill the pressure fluid tank using a special filling unit with
an integral filter (min. 10 µm).
2. Drop the system pressure right down by resetting the
pump. Set the pressure setting value on the pump pres- DANGER
sure control to minimum or zero pressure.
Ensure cleanliness during all work.
3. Fill and bleed the line system of the hydraulic product from
the unit to the cylinder. To do this actuate the cylinder in • Clean the external environment of couplings/joints and
both directions, see Operating Instructions. devices before disassembly. Do not use cleaning wool or
cloths containing fibres for cleaning.
4. Top up the pressure fluid volume to the specified quantity.
• Seal all openings using protective caps.
5. Raise the pump pressure to the system pressure.
• Bleed the hydraulic product after each item of repair work.
The hydraulic product is ready for operation.
• If appropriate, follow the procedure for bringing into first
6. Carry out a test run. use, see 9.3 Bringing into first use, subsequent bringing
7. Check the level of the fluid after the hydraulic product has into use.
warmed up to the operating temperature and adjust if nec- • Document any amendments/additional information that
essary. should be included in the Operating Instructions.
IMPORTANT
Check the contamination indicator when the pressure fluid is
warm (during or immediately after operation).
If the ambient temperature is low or the pressure fluid is cold,
its high viscosity may cause clogging to be apparently indi-
cated.
12.6 Servicing pressure accumulators
DANGER
Pressure accumulators are subject to the national legisla-
tion on safety requirements for pressure vessels applica-
ble in the place of installation.
Observe the Pressure Equipment Directive 97/23/EC.
IMPORTANT
The gas precharge pressure is measured with a testing and fill-
ing device.
Details of the procedure can be found in the Operating Instruc-
tions.
Inspection and servicing
• Carry out the tests required by law.
• Test and monitor the gas precharge pressure regularly.
12.7.1 General safety instructions for repair work

WARNING
Do not perform any welding, soldering or mechanical work
DANGER on accumulator vessels.
Repair work shall only be done by an authorised hydraulics Welding and soldering carry a risk of explosion!
expert who has the required specialist hydraulics knowl-
Mechanical tampering may cause the vessel to burst and
edge.
the operating permit will be withdrawn.
Specialist hydraulics knowledge means, among other things,
Do not charge hydrostatic accumulators with oxygen or air.
that the person can read and fully understand hydraulics draw-
Risk of explosion!
ings. In particular, he must fully comprehend the range of func-
tions of the integrated safety components. Depressurise the system before working on hydraulic
installations.
Components may only be dismantled for the purpose of repair
to the extent described in the Operating Instructions. Improper installation can lead to serious damage to per-
sons and property.
Never repair a defective safety valve. It must be completely
replaced.
Faulty parts may only be replaced by new, interchangeable,
tested components in original-equipment quality. Any devia- 13.2 Safety devices relating to
tions from this can be found in the Operating Instructions.
hydraulic pressure accumulators
Before each subsequent bringing into use after repair work, the
hydraulic product shall be accepted by a hydraulics expert. The equipping, installation and operation of hydrostatic accu-
The operator of the hydraulic product is required to check by mulators is regulated by the national implementation of the EU
means of a servicing record that the inspection and servicing Pressure Equipment Directive 97/23/EC and additionally in the
plan as been complied with. Federal Republic of Germany by the Technical Regulations for
Pressure Vessels (TRB). This legislation requires the following
Pressure vessels have to be pressure tested every 10 years safety equipment:
and the information recorded in accordance with the Pressure
Equipment Directive 97/23/EC or its implementation in national Ø Device to protect against excessive pressure
legislation. (prototype-tested)
Ø Pressure relief device
Ø Pressure measuring device
Ø Test gauge connection
13 General information about
Ø Shut-off device
hydraulic pressure accumulators
Ø Optional: electromagnetically operated pressure relief
device
13.1 General Ø Safety device to protect against overheating.
The regulations applicable at the place of installation concern-

ing hydraulic pressure accumulators (hydrostatic accumula- IMPORTANT
tors) must be observed before bringing into use and during
operation. See the Operating Instructions.
The plant operator bears sole responsibility for compliance with

the existing regulations.
Hydrostatic accumulators are subject to the national implemen-
tation of the EU Pressure Equipment Directive 97/23/EC.
Documents supplied with accumulators must be preserved
with care; they will be required during recurring inspections by
specialists.
The bringing into use of hydrostatic accumulators shall be car-
ried out by trained expert personnel only.
14 Hydraulic systems 14.1 Effects of leaks in the hydraulic system

on the machine
Hydraulic systems are generally intended for installation in
machines or systems. In addition to the basic information about If pressure fluid escapes from the hydraulic system and comes
the installed components, the information contained in the into contact with hot surfaces on the machine, this can lead to
Operating Instructions made available for each hydraulic sys- the generation of life-threatening smoke, fire and/or other dan-
tem by Bosch Rexroth also applies to hydraulic systems. gerous operating conditions.
By installing the hydraulic system in a machine or system, the These risks shall be determined by the machine manufacturer
interaction of the hydraulic system with the overall machine by means of a hazard analysis and if necessary provision made
may give rise to changes in the potential dangers. In particular for the appropriate safety devices.
the effect of hydraulic and electrical control of hydraulic drives
that create mechanical movement are to be considered.
This information shall be included in the hazard analysis/risk
assessment of the overall machine carried out by its supplier
and in the Operating Instructions of the overall machine. This
also applies to the specification of the interfaces between the
hydraulic system and the overall machine.
Hydraulic systems are subject to legislation including the Pres-
sure Equipment Directive and other relevant EU directives that
have been implemented in national legislation. Exact informa-
tion can be found in the EU Conformity Declaration or Manu-
facturer’s Declaration that is supplied with the hydraulic system
or the hydraulic product.
WARNING
Before installing a hydraulic system in a machine or mod-
ifying an existing hydraulic system in a machine, satisfy
yourself that
Ø the hydraulic system is suitable for its application in the
machine
Ø the ambient conditions in the machine are suitable and/or
permissible for the use of the hydraulic system
Ø other installed items on or in the machine cannot disturb
or endanger the functioning or the safe operation of the
hydraulic system.
If the overall machine is to be used in a potentially explosive

atmosphere, then it must be ensured that the hydraulic system
has been designed and is suitable for this use.
DE Bestellinformation für deutsche Produktinformation: RD 07008

EN Ordering Information for Product Information in English: RE 07008
FR Information de commande pour la notice française Informations générales sur les produits : RF 07008
IT Informazioni d’ordine per le informazioni tedesche sul prodotto: RI 07008
ES Información para el pedido de la información del producto en español: RS 07008
FI Tilaustiedot - suomenkieliset tuotetiedot: RSF 07008
NL Bestelinformatie voor Nederlandse productinformatie: RNL 07008
SV Beställningsnummer för svensk produktinformation: RSK 07008
PT Informação dos dados de encomenda para informação de produto alemã: RP 07008
DA Bestillingsinformationer vedr. dansk produktinformation: RDK 07008
EL Πληρφρίε παραγγελία για τι γερµανικέ πληρφρίε πρϊντ: RGR 07008
http://www.boschrexroth.com/bri-products
→ Datenblatt-Suche/Datasheet search
→ Suche nach Datenblatt/Search by datasheet
07008
Bosch Rexroth AG © All rights reserved, Bosch Rexroth AG, including applications for intellec-
Hydraulics tual property rights. We reserve all power of disposal, rights of reproduction
Zum Eisengiesser 1 and issue.
97816 Lohr am Main, Germany
The data specified above only serve to describe the product.
Tel. + 49 (0) 93 52 / 18-0
No statements concerning a certain condition or suitability for a certain
Fax + 49 (0) 93 52 / 18-23 58
application can be derived from our information. The given information does
documentation@boschrexroth.de
not release the user from the obligation of own judgement and verification. It
www.boschrexroth.de
must be remembered that our products are subject to a natural process of
wear and aging.
Bosch Rexroth AG
Drive & Control Support
Maria-Theresien-Straße 23
97816 Lohr am Main, Germany
Phone +49 9352 18-1041
Fax +49 9352 18-1040
trainingsystems.brs@boschrexroth.de
www.boschrexroth.de/trainingsystems
© This document, as well as the data, specifi-

cations and other information set forth in it, are
the exclusive property of Bosch Rexroth AG. It
may not be reproduced or given to third parties
without its consent.
The data specified above only serve to describe
the product. No statements concerning a
certain condition or suitability for a certain ap-
plication 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.
Printed in Germany
RE 00847/10.08
Mat. no. R961003873

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Project manual RE 00847/10.08

Proportional valve technology

Deceleration valves are used for the position-dependent, stepless accel-

Deceleration valve and cylinder with switching mechanism

Mechanically operated proportional valves were developed, which were actu-

Modern proportional directional valve with integrated On-Board Electronics (OBE)

Modern hydraulic press

Imparting knowledge through project work

The documentation should also be finally corrected, improved and completed.

Procedural In this manual, we do not give notes on procedural knowledge (explanatory

The present Project Manual Proportional Valve Technology includes warning

This symbol refers to a potential risk, which can lead to light or

This symbol refers to supplementary information.

Qualification of Installation, commissioning and operation, disassembly, upkeep and maintenance

Work carried out improperly on electrohydraulic components

If Projects 01 to 09 described in the Project Manual Proportional Valve Tech-

When using competitors' products, observe the safety notes

For this reason, commissioning is prohibited until it was estab-

In the description of Project exercises 01 to 07 in the Proportional Valve Tech-

Basic principles of proportional valve technology

A descriptive example is to illustrate the relationship of cross-section, pressure

The valve opening is to correspond to a bore of d = 5 mm, the system pressure

Structure and function

The valves basically consist of:

Characteristic To obtain as high a resolution as possible, up to three different spools with

This is to be illustrated with the help of an example :

Characteristic curves (measured with HLP46, q = 40 °C ± 5 °C)

30/l/min nominal flow at 10 bar valve pressure differential

Dp = Valve pressure differential (inlet pressure pP

Types of con- Proportional valves can be controlled in two different ways,

This principle offers some advantages:

Integrated On-Board Electronics (OBE)

Interface Integrated electronics (OBE) Valve

The electronics is located on the valve, thus forming a functional unit.

Amplifier cards (external electronics)

Simplified Power supply unit 1 provides all the required voltages.

Detailed functional description

The following is valid:

Standard Current Differential Command Direction of flow

[ ] = Cross-reference to the block circuit diagram

Signal Machine Command value Electrical Hydraulic Hydraulic

Digital signal Analog signal

External encoders such as switches, push-buttons, limit switches, pressure

Proportional directional valve with integrated electronics

Pressure control with integrated electronics

Analog command value module VT-SWMA-1

Analog control signals can be generated by various sources.

In industrial practice, the separate arrangement of command value generator

Operation of the command value module

Front of the VT-SWMA-1 command value module

This is to be illustrated by means of an example:

"4-Q“ is used for activating quadrant recognition.

Polarity of the Signal changes

e.g. emergency stop

In this way, all changes in the movement can be adjusted separately.

The following is valid for the ramps:

Value at test socket "t“ 3 2

The following is valid: t = 100 V ms Example: Ut = 5 V

Fundamental safety notes

Commissioning is therefore prohibited until it was established

• danger signs and safety notes on the machine

The operating instructions are intended for information purposes