1/8 RE 30095/04.11 Electric amplifiers Replaces: 05.02 Types VT 5005 to VT 5008 Component series 1X H5581_d Table of contents Features Contents Page – Suitable for the actuation of direct operated proportional directional valves with electr. position feedback Features 1 (type 4WRE, component series 1X) Ordering code 2 – Differential input Functional description 2 – Release input with LED display Block diagram / pinout: – "Ready for operation" message by LED display VT 5005 and VT 5006 4 – Step function generator and ramp generator Block diagram / pinout: VT 5007 and VT 5008 5 – Ramp times adjustable by means of a potentiometer (with VT 5005 and VT 5006 one ramp each, with VT 5007 Technical data 6 and VT 5008 four ramps each). In the condition as supplied, Display / setting elements 7 the ramps are set to 5 s Unit dimensions 7 – Four command values adjustable by means of the potentiom- Project planning / maintenance instructions / eter, call-ups indicated by LEDs additional information 8 – Controller for valve spool position – Two synchronized power output stages – Oscillator and demodulator for inductive position measure- ment with cable break detection – Reverse polarity protection for the voltage supply 2/8 Bosch Rexroth AG Hydraulics VT 5005 to VT 5008 RE 30095/04.11 Ordering code VT 500_ -1X * Amplifier with one ramp time: Further details in the plain text For valves type 4WRE 6 ..-1X = 5 = 1X Component series 10 to 19 For valves type 4WRE 10 ..-1X = 6 (10 to 19: Identical technical data and pinout) Amplifier with five ramp times: For valves type 4WRE 6 ..-1X = 7 For valves type 4WRE 10 ..-1X = 8 Accessories (not included in scope of delivery) Card holder: Type VT 3002-1-2X/32D, see data sheet 29928 Functional description Example: If command value 1 and command value 3 are acti- Using the command value inputs 1 to 4, command values vated simultaneously, command value 3 will take effect. can be retrieved [1] by actuating the related relays (K1 to K4). The command value voltage is either specified direct- Another output of the card supplies a feed voltage for the ly, by the controlled voltages ±9 V of the internal power sup- command value calls which can be switched from +9 V to 1) ply [12] or via an external command value potentiometer. To –9 V by means of the relay K6 . 1) these inputs, the following applies: ±9 V ≙ ±100 % . If these For the amplifier variants with 5 ramp times (VT 5007 and four command value inputs are directly connected to the con- VT 5008), each of the four call-up command values is allocat- trolled voltages ±9 V, four different command values can be ed an adjustable ramp time ("t1" to "t4"). If no command value set at the "w1" to "w4" potentiometers. When using external is called, the time "t5" will take effect in these devices. For the command value potentiometers at these inputs, the internal amplifier variants with one ramp time (VT 5005 and VT 5006), potentiometers will function as attenuators or limiters unless the time "t" is effective for all command values at all times. they are set to the maximum. All relays on the card are switched with 24 VDC (smoothened). External command value potentiometers The command value input 5 is a differential input (0 to ±10 V). Inputs 14c (14a, 20a, 20c) If the command value is specified by external electronics 24a with a different reference potential, this input has to be used. 5 K ���� Actuation When disconnecting or connecting the command value volt- 26c Solenoid "b" M0 age, it has to be ensured that both signal lines are in each 28c case separated from or connected with the input. Before they are forwarded, all command values will be added 14c (14a, 20a, 20c) Inputs up according to their absolute value and their sign [3]. 26a The down-stream ramp generator [4] generates a ramp- 5 K ���� Actuation shaped output signal from given a step-shaped input signal. 26c Solenoid "a" M0 The time constant of the output signal can be set using the po- 28c tentiometers "t" or "t1" to "t5". The specified ramp time refers to a command value step of 100 % and may be approx. 1s or 14c (14a, 20a, 20c) Inputs 5s, depending on the jumper setting (J5, J6). If a command value step of less than 100 % is switched to the ramp genera- 26a ���� 5 K Actuation tor input, the ramp time will be correspondingly shorter. 24a Solenoid "a"+"b" ���� 28c The LEDs "H1" to "H4" indicate which command value is just being called. If more than one command value is called at a time, the input with the highest number will take priority. 1) The reference potential for the command values 1 to 4 is M0 (measurement null). 3/8 RE 30095/04.11 VT 5005 to VT 5008 Hydraulics Bosch Rexroth AG Functional description External time potentiometer and ramp "Off" In case of failure-free operation, the "H12" LED (ready for op- eration) is illuminated; in detail if: 8a – The release signal is applied, 500 K Ramp "controllable" 10a – The internal ±9 V voltage supply functions 28c (amplitude and symmetry), – No short-circuit of the solenoid lines and 8a – There is no cable break in the position transducer lines. Ramp "On/Off" 10a In case of failure, the two output stages are immediately de- energized, the controller is switched off and the "Ready for Important: operation" message is reset. After remedy of the failure, the When using an external time potentiometer, the internal po- card is immediately functional again; the "H12" LED lights tentiometer for the ramp time must be set to maximum. The up again. maximum ramp time is reduced as the resistance value of the external potentiometer is switched in parallel to that of the internal one (approx. 500 kΩ). By switching the relay K5 or by an external bride, the ramp [ ] = Allocation to the block diagram on page 4 and 5 time is set to its minimum value (approx. 30 ms). The output signal of the ramp generator [4] is lead in parallel to the summing device [6] and the step function generator [5]. With command value voltages > 100 mV, the step function generator [5] generates a polarity-independent step signal that is added to the output signal of the ramp generator. This step function results in the fast passing of the valve spool overlap. With larger command value voltages, the step func- tion generator emits a constant output signal. The output signal of the summing device [6] is the position command value and is supplied to the PID controller [7], the "w" measurement socket on the front panel of the card and port 4a (command value after ramp/external limitation poten- tial). A voltage of –6 V at the "w" measurement socket corre- sponds to a command value of +100 %. The PID controller has been especially optimized for the 4WRE valve type (component series 1X). The current output stages are actuated depending on the difference between po- sition command value and actual position value. A positive command value signal at the amplifier input actuates the out- put stage for solenoid "a", a negative command value signal the output stage for solenoid "b". The inductive position transducer [13] detects the valve spool position. The AC voltage signal of the position transducer is converted in the oscillator/demodulator [11] and returned to the PID controller as actual position value. The zero point of the position transducer (actual value zero point) can be adjusted by means of the "Zx" potentiometer (on the printed circuit board). The amplification of the actual position value has been calibrated in the factory and must not be changed (±6 V ≙ max. valve spool stroke). With a signal of > 8.5 V at the release input (available from component series 17), the output stages (indication by the yel- low "H11" LED on the front plate). By setting jumper J7, the output stages are permanently released irrespective of the re- lease input status. The release input will then be ineffective. 4/8 Bosch Rexroth AG Hydraulics VT 5005 to VT 5008 RE 30095/04.11 Block diagram / pinout: VT 5005 and VT 5006 (from component series 17) Measurement socket "w": –6 V ≙ +100 % Ready 2c Measurement socket "x": +6 V ≙ +100 % for op- � PI eration 32c � Magnet 8a F "b" 8 9 Ramp external 10a Differential input 6c Reference potential/GND u 10 15 6a u Command value 5 ±10 V 2 20c F Command value 4 ±9 V w K5 20a 8 9 Command value 3 ±9 V 14a 2a Command value 2 ±9 V Magnet F � 14c F F F F PI t 5 32a Command value 1 ±9 V � "a" w1 w2 w3 w4 Command value+ (– at (R1) (R2) (R3) (R4) "w" measurement socket) 4 3 results in the actuation of F solenoid "a". x ∑ ∑ 1 PID Command value– (+ at K4 7 K3 "w" measurement socket) J5, J6 K2 K1 6 results in the actuation of 4c Actual position solenoid "b". value ±6 V + 14 30a K6 H10 Auxiliary voltage ±9 V – 4a Command value F Call-ups 1 K1 12c H1 after ramp ±6 V Command value 1 F 8c 12a K2 H2 Release Gx Command value 2 F F 16a K3 H3 Command value 3 10c Zx 1 F � 16c K4 13 H4 Command value 4 � 18a K5 30c 2 Ramp Off 11 K6 18c 28c Switch-over 14 0 V auxiliary voltage 22c 24c Relay call-up Release input voltage (+24 V) "Release" internal 12 J7 26a 2,5 A T Measurement null +9 V 22a � + U 26c B (M0) is increased M0 Operating 24a 2200 μF by 9 V as compared –9 V voltage 28a to the 0 V operating 0 V F = On front plate voltage! 1 Command values 7 Controller for spool position H1…H4 LED display for command value call-ups 2 Differential amplifier 8 Current controller 12 Power supply K1…K6 Call-up relay 3; 6 Summing device 9 Output stage 13 Position transducer R1…R4 Command value potentiometer 4 Ramp generator 10 Monitoring 14 Threshold detection t Ramp time 5 Step function 11 Oscillator/demodulator 15 Proportional valve 5/8 RE 30095/04.11 VT 5005 to VT 5008 Hydraulics Bosch Rexroth AG Block diagram / pinout: VT 5007 and VT 5008 (from component series 17) Measurement socket "w": K1.2 Ready 2c –6 V ≙ +100 % K2.2 K3.2 for op- � 8a K4.2 PI Measurement socket "x": eration 32c � Magnet Ramp external 10a F F F F F t1 t2 t3 +6 V ≙ +100 % F t5 t4 "b" 8 9 Diffearential input 6c 10 15 Reference potential/GND u 6a Command value 5 ±10 V u 2 F 20c w Command value 4 ±9 V K5 9 20a 8 Command value 3 ±9 V 2a Magnet 14a � Command value 2 ±9 V PI "a" 5 32a 14c � F F F F Command value 1 ±9 V w1 w2 w3 w4 Command value+ (– at (R1) (R2) (R3) (R4) "w" measurement socket) 3 4 results in the actuation of F x solenoid "a". ∑ ∑ 1 PID K4 Command value– (+ at K3 7 "w" measurement socket) K2 J5, J6 K1 6 4c results in the actuation of Actual position solenoid "b". value ±6 V + 14 K6 30a H10 Auxiliary voltage ±9 V – 4a Command value Call-ups F 1 12c K1 after ramp ±6 V H1 Command value 1 F 12a 8c K2 Release H2 Command value 2 Gx F F 16a K3 H3 Command value 3 Zx 10c 1 F � 16c K4 H4 13 Command value 4 � 18a Ramp Off K5 30c 2 Switch-over 18c K6 28c 11 14 0 V auxiliary voltage 22c Relay call-up 24c Release input voltage (+24 V) "Release" internal 12 J7 26a Measurement null 2,5 A T +9 V 22a � + U 26c B (M0) is increased M0 Operating 24a by 9 V as compared 2200 μF voltage –9 V 28a to the 0 V operating F = on front plate 0 V voltage! 1 Command values 7 Controller for spool position H1…H4 LED display for command value call-ups 2 Differential amplifier 8 Current controller 12 Power supply K1…K6 Call-up relay 3; 6 Summing device 9 Output stage 13 Position transducer R1…R4 Command value potentiometer 4 Ramp generator 10 Monitoring 14 Threshold detection t1...t5 Ramp time 5 Step function 11 Oscillator/demodulator 15 Proportional valve 6/8 Bosch Rexroth AG Hydraulics VT 5005 to VT 5008 RE 30095/04.11 Technical Data (For applications outside these parameters, please consult us!) Operating voltage U 24 VDC +40 % –5 % B Operating range: – Upper limit value u (t) 35 V B max – Lower limit value u (t) 22 V B min Power consumption P < 50 VA S Current consumption I < 2 A Fuse I 2.5 A T S Inputs: – Command values 1 to 4 U ±9 V (reference potential is M0) e – Command value 5 U 0 to ±10 V; R ≥ 100 kΩ e e – Release ∙ Active U > 8.5 V F ∙ Not active U < 6.5 V F Relay data: – Nominal voltage U Operating voltage U B – Response voltage U 16.8 V – Reverse voltage U 2.4 V – Coil resistance R 2150 Ω Ramp time (setting range) t 30 ms to approx. 1 s or 5 s (in each case ±20 %) Outputs: – Output stage • Solenoid current/resistance VT 5005, VT 5007 I 1.8 A ± 20 %; R = 5.4 Ω max (20) VT 5006, VT 5008 I 2.2 A ± 20 %; R = 10 Ω max (20) • Clock frequency f Self-clocking up to approx. 1.5 kHz – Driver for the inductive position transducer: • Oscillator frequency f 2.5 kHz ±10 % • Maximum load capacity I 30 mA • Voltage amplitude U 5 V per output SS – Controlled voltage U ±9 V ±1 %, 25 mA externally loadable – Measurement sockets • Command value "w" U 0 to ±6 V (–6 V ≙ +100 %; +6 V ≙ –100 %); R = 100 Ω w i • Actual position value "x" U 0 to ±6 V (+6 V ≙ +100 %; –6 V ≙ –100 %); R = 100 Ω x i Type of connection 32-pole blade connector, DIN 41612, design D Card dimensions Euro board 100 x 160 mm, DIN 41494 Front plate dimensions: – Height 3 HE (128.4 mm) – Width conductor path side 1 TE (5.08 mm) – Width component side 7 TE Admissible operating temperature range ϑ 0 to 50 °C Storage temperature range ϑ –20 to +85 °C Weight m 0.15 kg 7/8 RE 30095/04.11 VT 5005 to VT 5008 Hydraulics Bosch Rexroth AG Display / setting elements H10 - red LED Max. ramp time Zx: Gx: approx. 1 s or 5 s Zero point Gain of the actual posi- "cable break" position transducer tion value (calibrated in the factory) LED display "Release" (yellow) LED display "Ready for operation" (green) J6 w1/H1 Command value 1 with LED display t1 w2/H2 Command value 2 with LED display w1 J5 t2 w3/H3 Command value 3 with LED display w2 t3 w4/H4 Command value 4 with LED display w3 t4 t Ramp time (for VT 5005 and VT 5006) w4 t5 t1... t5 Ramp times (for VT 5007 and VT 5008) F1 t 2,5 A T x Measurement socket for actual position value w Measurement socket for command value �� Slip-on board for variants Release with five ramp times (from component series 17) Meaning of the jumpers on the card for the settings (plate on the back side of the front plate) Important: The circles ( ) serve the marking of the Jumper plugged ramp time enable Jx = bridge settings made by the customer. 5 s J5 J6 int. J7 Jx = open The condition is supplied is marked with "•". Bridge or open 1 s J5 J6 ext. J7 = delivery state Ramp time Release Unit dimensions (dimensions in mm) w t 1 w 1 H H w w t 2 2 H H w w t 3 3 H H w w t 4 4 H H t t 5 x x w w : M0 : M0 ±6 V:= 100 % ±6 V:= 100 % 8TE (40,3) 8TE (40,3) 2 165 7 182 3HE (128,4) 100 89 X1 8/8 Bosch Rexroth AG Hydraulics VT 5005 to VT 5008 RE 30095/04.11 Project planning / maintenance instructions / additional information – The amplifier card may only be unplugged and plugged when de-energized! – No plug-in connectors with free-wheeling diodes or LED indicators must be used for solenoid connection! – Only carry out measurements at the card using instruments R > 100 kΩ! i – Measurement null (M0) is increased by +9V compared to 0 V operating voltage and not isolated, i.e. –9 V controlled voltage = 0 V operating voltage. Thus, do not connect measurement null (M0) to 0 V operating voltage! – For switching command values, relays with gold-plated contacts have to be used (small voltages, low currents)! – Card relays may only be switched using contacts with a load capacity of approx. 40 V, 50 mA! In case of actuation, the control voltage must have a residual ripple of max. 10 %! – Always shield command value lines; connect shielding to 0 V operating voltage on the card-side, other side open (risk of ground loops)! Recommendation: Also shield solenoid lines! For solenoid lines up to a length of 50 m, use the cable type LiYCY 1.5 mm². With greater lengths please contact us! – The distance to aerial lines, radios, and radar systems has to be 1 m at least! – Do not lay solenoid and signal lines near power cables! – The charging current of the smoothing capacitor on the card requires the series fuses to be of a slow-blowing nature! – Do not connect the ground sign at the inductive position transducer with the ground! (Prerequisite for the compatibility with previous component series!) – Attention: If the differential input is used, both inputs must always be connected or disconnected at the same time! Note: Electric signals taken out via control electronics (e.g. "Ready for operation" signal) must not be used for switching safety-relevant machine functions! (See also the European standard "Safety requirements for fluid power systems and their components - Hydraulics", EN 982) Bosch Rexroth AG © This document, as well as the data, specifications and other informa- Hydraulics tion set forth in it, are the exclusive property of Bosch Rexroth AG. It Zum Eisengießer 1 may not be reproduced or given to third parties without its consent. 97816 Lohr am Main, Germany The data specified above only serve to describe the product. No state- Phone +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain applica- Fax +49 (0) 93 52 / 18-23 58 tion can be derived from our information. The information given does not documentation@boschrexroth.de release the user from the obligation of own judgment and verification. It www.boschrexroth.de must be remembered that our products are subject to a natural process of wear and aging.