Electro-hydraulic control with proportional solenoid EP...EP - Electro-hydraulic control with proportional solenoid The EP control adjusts the pump displacement proportional to the

IndustrialHydraulics

Electric Drivesand Controls

Linear Motion andAssembly Technologies Pneumatics

ServiceAutomation

MobileHydraulics

RA 92 084/12.04 1/16

Technical data sheet

Electro-hydraulic controlwith proportional solenoid EP

for variable pump(A)A4CSG series 3(A)A4VSG series 1and 3closed circuit

Features– Electro-proportional control current dependent

– High control accuracy

– With fail-safe to zero flow on power loss

– Emergency manual override

– Use of standard proportional amplifiers possible

Further information:

Variable pump (A)A4CSG Size 250...750 RA 92105

Variable pump (A)A4VSG Size 40...1000 RA 92100

ContentsOrdering code 2

EP - Electro-hydraulic control with proportional solenoid 3

Technical data and circuit schematic 4

Pressure control 5

EPA with pressure control for port A only 6

EPGA with remote pressure control in port A only 7

EPB with pressure control in port B only 8

EPGB with remote pressure control in port B only 9

EPD with pressure control in both ports A and B 10

EPG with remote pressure control in both ports A and B 11

Unit dimensions EP 12

Unit dimensions EPA / EPGA 13

Unit dimensions EPB / EPGB 14

Unit dimensions EPD / EPG 15

Type of connector 16

Safety information 16

2/16 Bosch Rexroth Corp. | Industrial Hydraulics (A)A4CSG..EP | RA 92 084/12.04

A4 G EP... / –

Ordering code

Dire

ctio

n of

rota

tion

Ser

ies

Sha

ft en

d

Sea

ls

Mou

ntin

g fla

nge

Ser

vice

por

ts

Thro

ugh

driv

e

Boo

st p

ump

● = available ❍ = in preparation

Val

ves

Axial piston unitCompact unit, ● (A)A4CSswash plate design, variable

Swash plate design, variable ❍ (A)A4VS

Type of operationPump, closed circuit G

SizeDisplacement Vg max (cm

3) 40 71 125 180 250 355 500 750 1000

Control and adjustment devices

Electro-hydraulic control, with proportional solenoid EP...

Pressure control 40 71 125 180 250 355 500 750 1000without pressure control – without code ❍ ❍ ❍ ❍ ● ● ❍ ❍ ❍

with pressure control in A ❍ ❍ ❍ ❍ ● ● ● ● ❍ .. A

with remote pressure control in A ❍ ❍ ❍ ❍ ● ● ● ● ❍ ..GA

with pressure control in B ❍ ❍ ❍ ❍ ● ● ● ● ❍ ..B

with remote pressure control in B ❍ ❍ ❍ ❍ ● ● ● ● ❍ ..GB

with pressure control both sides ❍ ❍ ❍ ❍ ● ● ● ● ❍ ..D

with remote pressure control both sides ❍ ❍ ❍ ❍ ● ● ● ● ❍ ..G

For detailed data see: RA 92105 – (A)A4CSG

RA 92100 – (A)A4VSG

Filtr

atio

n

RA 92 084/12.04 | (A)A4CSG..EP Industrial Hydraulics | Bosch Rexroth Corp. 3/16

740

280

280

740

1,0 0,8 0,6 0,4 0,2 0 0,2 0,4 0,6 0,8 1,0

15°

0° 1

5°

rechtslinks

EP - Electro-hydraulic control with proportional solenoidThe EP control adjusts the pump displacement proportional to the solenoid current.

The mechanical feedback system ensures a reliable and secure center (zero flow) position on power loss. This push-back to zeroflow position is assisted by the standard spring centering.

There are two solenoids: one for each swivel direction.

Standard is an emergency manual override on each solenoid. On actuation, these enable an adjustment of displacement from zeroto Vgmax (proportional to applied force).

To control the solenoids, we recommend the use of current controlled amplifiers with PWM-signal (pulse width modulation),eg. VT 10159 (corresponds to VT 3000 but with 100 Hz see RE 29935). Some applications may use digital controller RC withamplifier software DSD (dual solenoid driver), see RE 95200 or amplifier RA2-1/10, see RE 95230. Please order separately.

Flows in both swivel directions can be limited by mechanical stops between Vgmax and 50% Vgmax, for the size 500 between Vgmaxand 70% Vgmax.

Relation betweenDirection of rotation-solenoid-direction of flow

Direction Solenoid Swivel Direction Pressureof rotation range1) of flow side

clockwise b right B to A A

a left A to B B

counter- b right A to B B

clockwise a left B to A A1) compare swivel angle indicator.

I in mA (solenoid a)

I in mA (solenoid b)

VgVg max

–VgVg max

Characteristic

rightleft


ba

E2 E1 MSSU

B AMB MAK1

E3

ME3

MABP

K4

MK4

M1 M2R(L)TK2 K3

Technical data and circuit schematic

Technical data – hydraulics

Size 40 71 125/180 250/355 500 750

Stroke of control piston smax in (mm) 0.56(14,2) 0.67(17,1) 0.81(20,7) 1.02(25,9) 1.28(32,6) 1.46(37)

Area of control piston A in2 (cm2) 0.60(3,9) 0.99(6,4) 1.40(9) 2.23(14,4) 2.91(18,8) 4.42(28,5)

Control volume VSmax in3 (cm3) 0.34(5,5) 0.67(11) 1.14(18,7) 2.28(37,3) 3.75(61,4) 6.41(105)

Min. required control pressure pmin psi (bar) double boost pressure in M1 (measuring port small control chamber)

Control time* approx.at 2900psi (200 bar) high press. t s 0,08 0,15 0,15 0,3 0,4 0,7

Hysteresis 5...7 % of VgmaxRepeatability < 2 % of Vgmax* with integrated pressure control longer control times are possible, dependent on difference between actual load pressureand pressure control setting.

Circuit schematic EPExample (A)A4CSG250EP/30X-XXXXXFXX4N

Technical data – electrical (sizes 125 ... 1000)

Operating voltage 24V

Nominal current 800 mA

Control currentBeginning of control at Vg0 280 mA

End of control at Vgmax 740 mA

Current limit at Umax 1,05 A

Nom. resistanceat 68°F R68 (at 20°C R20) 19 Ω

Max. duty cycle 100% (S1)

Dither frequency 100 – 200 Hzfor PWM-signal (Recommended 100 Hz)

Class of isolation F (Tmax = 310°F (155°C))

Type of plug DIN EN 175 301-803/ISO 4400see page 16

Protection to DIN/EN 60529 IP 65

Emergency override Pressure plate in rubber cap

Force to actuate 41 lbf (180 N) for Vgmaxmanual override

Operating temperature coils 266°F (130°C) Danger: seesafety information page 16

proportional valve

hydrauliccontrol device

Formula for calculation of resistance

at T > 68 °F at T > 20 °C

RW =R68 x (391 + T°F)

459in°F RW =

R20 x (235 + T°C)

255in°C


Pressure controlThe pressure control (pressure compensator) is an optional function that regulates the pump displacement, as soon as a presetpressure value is reached. This max pressure is set at the pressure control valve, and if this pressure is exceeded, the pressurecontrol valve opens and destrokes the pump until the preset pressure value is reached again.

The pressure control is available as an option: EPA in port A only (circuit drawings see page 6)EPB in port B only (circuit drawings see page 8)EPD in both ports A and B (circuit drawings see page 10)

Adjustment range 725...5100 psi (50...350 bar)

Standard setting of pressure control is 5100 psi (350 bar), other settings please state in clear text when ordering. The pressurecontrol settings must be at least 435 psi (30 bar) lower than the settings of the high pressure relief valves ((A)A4CSG), in order toavoid that the high pressure relief valves open before the pressure control is activated (heat generation and waste of energy).

Characteristic

VgVgmax

High press. relief setting (max. 5500 psi (380 bar))

Adjustment of relief valves at beginning of opening

Pressure control

Adjustment directly at pressure control valve (EPA, EPB, EPD)or at remote pressure relief (EPGA, EPGB, EPG)(see instructions about setting)

435

psi

(30

bar)

Displacement

Ope

ratin

g pr

ess.

pA

,B

Remote pressure controlRemote setting of pressure control is accomplished via ports XA and or XB, using a remote relief valve.

The external pressure relief valves are not part of the supply.

Recommended: direct operated relief valve DBD 6 (RA 25 402)

Max. line length between pump and external relief valve not to exceed 7 ft (2 m).

Standard setting of differential pressure at pressure control valve 435 psi (30 bar). Pilot oil consumption in this caseapprox. 0.5 gpm (2L/min).

If a different setting is required please state in clear text (range 200 - 725 psi (14 - 50 bar)).

Information for adjustment of remote pressure control:

Setting of external pressure relief valve plus differential pressure at pressure control valve = pressure control setting.

Example: external pressure relief valve: 4640 psi (320 bar)

differential pressure at pressure control valve: 435 psi (30 bar)

results in pressure control setting of 4640 + 435 = 5075 psi(320 + 30 = 350 bar)

Optional remote pressure control : EPGA in port A only (circuit drawing see page 7)EPGB in port B only (circuit drawing see page 9)EPG in both ports A and B (circuit drawing see page 11)


E2 E1 MSSUMABP M1 M2R(L)TK2 K3

ba

E3ME3

K4

MK4

B AMB MAK1

S MSU R(L)TK3K2MAB E2 E1

K4

MK4

ME3E3

a b

B AMB MAK1

M1M2

EPA with pressure control for port A onlyThe pressure control valve regulates the pressure in port A.Description see page 5.

Circuit schematic sizes 250 and 355

Press. control valve,direction of rotationclockwise

Press. control valve,direction of rotationcounter-clockwise




PortsM1 Measuring port small control chamberM2 Measuring port large control chamber




ba

E3ME3

K4

MK4

B AMB MAK1

XA


K4

MK4

ME3E3

a b

B AMB MAK1

M1M2

XA XA

XAPress. control valve,direction of rotationclockwise


EPGA with remote pressure control in port A onlyRemote setting of pressure control is accomplished via port XA. The external relief valve is not included in the supply.Description see page 5.





External relief valveis not part of supply


PortsXA Pilot port remote pressure control in AM1 Measuring port small control chamberM2 Measuring port large control chamber

PortsXA Pilot port remote pressure control in AM1 Measuring port small control chamberM2 Measuring port large control chamber



ba

E3ME3

K4

MK4

B AMB MAK1


K4

MK4

ME3E3

a b

B AMB MAK1

M1M2






EPB with pressure control in port B onlyThe pressure control valve regulates the pressure in port B.Description see page 5.






ba

E3ME3

K4

MK4

B AMB MAK1

XB XB


K4

MK4

ME3E3

a b

B AMB MAK1

M1M2

XB XB



EPGB with remote pressure control in port B onlyRemote setting of pressure control is accomplished via port XB. The external relief valve does not belong to the supply.Description see page 5.







PortsXB Pilot port remote pressure control in BM1 Measuring port small control chamberM2 Measuring port large control chamber

PortsXB Pilot port remote pressure control in BM1 Measuring port small control chamberM2 Measuring port large control chamber



K4

MK4

ME3E3

a b

B AMB MAK1

M1M2


ba

E3ME3

K4

MK4

B AMB MAK1

Circuit schematic EPD sizes 250 and 355

EPD with pressure control in both ports A and BTwo pressure relief valves control the pressure independently in ports A resp. B.Description see page 5.

Press. control valves,direction of rotationcounter-clockwise

Circuit schematic EPD sizes 500 and 750

Press. controlvalves,direction ofrotationclockwise

Press. controlvalves,direction ofrotationcounter-clockwise



Press. control valves,direction of rotationclockwise



K4

MK4

ME3E3

a b

B AMB MAK1

M1M2

XBXA XA XB


ba

E3ME3

K4

MK4

B AMB MAK1

XA XB XB XA

Press. control valves,direction of rotationcounter-clockwise

EPG with remote pressure control in both ports A and BThe remote setting of pressure is accomplished via ports XA and XB. The external relief valves do not belong to the scope off supply.Description see page 5.


Press. controlvalves,direction ofrotationclockwise

Press. controlvalves,direction ofrotationcounter-clockwise

Circuit schematic EPG sizes 500 und 750


Circuit schematic EPG sizes 250 and 355

PortsXA Pilot port for remote pressure control in AXB Pilot port for remote pressure control in BM1 Measuring port small control chamberM2 Measuring port large control chamber

PortsXA Pilot port for remote pressure control in AXB Pilot port for remote pressure control in BM1 Measuring port small control chamberM2 Measuring port large control chamber

Press. control valves,direction of rotationclockwise


KU

T B S

9.57

(243

)10

.98

(279

)9.

92 (2

52)

1

RL

R(L) M2

M

Unit dimensions EPSizes 250 and 355

Before finalising your design pleaserequest a certified installation drawing.Dimensions in inches (mm).

1) see safety information

Proportional valve

Hydraulic controldevice

Emergency overridesolenoid A

Emergency overridesolenoid B

Ports max. tightening torque 1)M1 Measuring port small control chamber DIN 3852 M18x1,5; 0.47(12) deep (plugged) 103 lb.ft (140 Nm)M2 Measuring port large control chamber DIN 3852 M18x1,5; 0.47(12) deep (plugged) 103 lb.ft (140 Nm)

For detailed dimensions and technical data of the variablepump see the main data sheets (A)A4CSG RA 92105 or(A)A4VSG RA 92100.


XA

A3

A5

A4

A7

B)3

XA

A1

A2

A6

1

R(L) M2

M

M10

x1.0

0M

8 (x

1.25

)M

8 (x

1.25

)

M5 (x0.8) M5 (x0.8)

M5 (x0.8)M5 (x0.8)

M16 (x2)

M16 (x2)

M20 (x2.5)M20 (x2.5)M20 (x2.5)M20 (x2.5)

Schl.weite: 19 mm

M36

x2

Schl.weite: 55 mm

Schl.weite: 55 mm

B

R(L)

XA

R(L)

XA

A1

A6

A2

A3

A5

A4

1

M2

M

Press. control valve

Press. control valve

Unit dimensions EPA / EPGA

Unit dimensionsSize A1 A2 A3 A4 A5

3) A6 A7250 9.92(252) 10.98(279) 9.57(243) 16.93(430) 8.98(228) 0.51(13) 9.84(250)

355 9.92(252) 10.98(279) 9.57(243) 16.93(430) 8.98(228) 0.51(13) 9.84(250)

500 12.05(306) 13.07(332) 13.46(342) 18.46(469) 12.40(315) 5.35(136) –

750 12.40(315) 13.07(332) 14.65(372) 19.72(501) 13.58(345) 5.35(136) –

1) see safety information 2) plugged 3) version EPA size 250 and 355 without adaptor

Ports max. tighteningXA Pilot port for remote pressure torque

1)

control in A (with EPA plugged)3) ISO 11926 9/16-18UNF-2B 0.51(13) deep (Size 250 a. 355) 59lb-ft(80Nm)DIN 3852 M14x1,5; 0.47(12) deep (Size 500 a. 750) 59lb-ft(80Nm)

M1 Measuring port small control chamber DIN 3852 M18x1,5; 0.47(12) deep 2) (Size 250 a. 355) 103lb-ft(140 Nm)

M22x1,5; 0.55(14) deep 2) (Size 500 a. 750) 155lb-ft(210 Nm)M2 Measuring port large control chamber DIN 3852 M18x1,5; 0.47(12) deep

2) (Size 250 a. 355) 103lb-ft(140 Nm)M14x1,5; 0.47(12) deep 2) (Size 500 a. 750) 59lb-ft(80Nm)

Sizes 500 and 750Sizes 250 and 355


to mounting flange

to mounting flange

For detailed dimensions andtechnical data of the variablepump see main data sheet(A)A4CSG RA 92105 or(A)A4VSG RA 92100.

Solenoid BSolenoid B

Solenoid ASolenoid A


XB

XB

A1

A3

A2

A5

A4

A6

A8

1

)3

B

R(L) M2

M

M5 (x0.8) M5 (x0.8)

M5 (x0.8)M5 (x0.8)

M16 (x2)M16 (x2)

M20 (x2.5)M20 (x2.5)

M36

x2M

36x2Schl.weite: 55 mm

Schl.weite: 55 mm

B

R(L)

XB

XB

A1

A2

A6

A3

A7

A4

R(L)

1

M2

M

Sizes 500 and 750

Unit dimensions EPB / EPGBSizes 250 and 355

Unit dimensions

Size A1 A2 A3 A4 A53) A6 A7 A8

250 9.92(252) 10.98(279) 9.57(243) 16.93(430) 8.98(228) 0.51(13) – 9.84(250)

355 9.92(252) 10.98(279) 9.57(243) 16.93(430) 8.98(228) 0.51(13) – 9.84(250)

500 12.05(306) 13.07(332) 13.46(342) 18.46(469) – 5.35(136) 11.97(304) –

750 12.40(315) 13.07(332) 14.65(372) 19.72(501) – 5.35(136) 11.97(304) –


Solenoid A

Solenoid B

Ports max. tighteningXB Pilot port for remote pressure torque

1)

control in B (with EPB plugged)3) ISO 11926 9/16-18UNF-2B 0.51(13) deep (Size 250 a. 355) 59lb-ft(80Nm)DIN 3852 M14x1,5; 0.47(12) deep (Size 500 a. 750) 59lb-ft(80Nm)




For detailed dimensionsand technical data of thevariable pump see maindata sheets (A)A4CSGRA 92105 or (A)A4VSGRA 92100.

Solenoid A

Solenoid B

to mounting flange

to mounting flangePressure control valve

Pressure control valve

1) see safety information 2) plugged 3) version EPB size 250 and 355 without adaptor


XA XB

XA XB

A3

A5

A4

A7

A1

A2

A6

A8

1

)3

B

R(L) M2

M

B

R(L)

XA XB

XA

XB

A1

A6

A2

A6

A3

A5

A7

A4

R(L)

1

M2

M

Unit dimensions EPD / EPGSizes 500 and 750Sizes 250 and 355


Solenoid A

Solenoid B

Ports max. tighteningXA, XB Pilot port for remote pressure torque

1)

control (with EPD plugged)3) ISO 11926 9/16-18UNF-2B 0.51(13) deep (Size 250 a. 355) 59lb-ft(80Nm)DIN 3852 M14x1,5; 0.47(12) deep (Size 500 a. 750) 59lb-ft(80Nm)




to mounting flange

to mounting flange

to mounting flange

Press. control valve B

Press. control valve A

1) see safety information 2) plugged 3) version EPD size 250 and 355 without adaptor

Unit dimensions

Size A1 A2 A3 A4 A53) A6 A7 A8

250 9.92(252) 10.98(279) 9.57(243) 16.93(430) 8.98(228) 0.51(13) 18.43(468) 9.84(250)

355 9.92(252) 10.98(279) 9.57(243) 16.93(430) 8.98(228) 0.51(13) 18.43(468) 9.84(250)

500 12.05(306) 13.07(332) 13.46(342) 18.46(469) 12.40(315) 5.35(136) 11.97(304) –

750 12.40(315) 13.07(332) 14.65(372) 19.72(501) 13.58(345) 5.35(136) 11.97(304) –

Solenoid BPress. control valve B

Solenoid A Press. control valve A

Detailed dimensions andtechnical data of thevariable pump see maindata sheets (A)A4CSGRA 92105 or (A)A4VSGRA 92100.


© 2004 Bosch Rexroth Corporation

All rights reserved. Neither this document, nor any part of it, may be reproduced,duplicated, circulated or disseminated, whether by copy, electronic format or anyother means, without the prior consent and authorization of Bosch RexrothCorporation.

The data and illustrations in this brochure/data sheet are intended only todescribe or depict the products. No representation or warranty, either express orimplied, relating to merchantability or fitness for intended use, is given orintended by virtue of the information contained in this brochure/data sheet. Theinformation contained in this brochure/data sheet in no way relieves the user ofits obligation to insure the proper use of the products for a specific use or

Bosch Rexroth CorporationMobile HydraulicsAxial & Radial Piston Units8 Southchase CourtFountain Inn, SC 29644-9018USATelephone (864) 967-2777Facsimile (864) 967-8900www.boschrexroth-us.com

Type of connectorHirschmann-connectorto DIN EN 175301-803/ISO 4400

Type of protection IP 65

Male plug:

to DIN EN 175 301–803/ISO 4400 with screw cable gland M16x1,5 for cable Dia 0.18...0.39 (ø 4,5...10mm) does not belong tois not part of the supply of the EP control, however is available under the following Rexroth part numbers: R902602623 (black)

or R902602622 (grey)

Safety information– The pump (A)A4V(C)SG is designed for operation in closed circuits.

– Systems design, installation and commissioning requires trained technicians engineers or tradesmen.

– All hydraulic ports can only be used for the fastening of hydraulic service lines.

– Tightening torques: all max. tightening torques, mentioned in this data sheet are maximum values and cannot be exceeded(they represent the max. permissible value for the female threads in the castings)

For fastening screws to ISO 68/DIN 13 we recommend to check the permissible tightening torques in eachindividual case acc. to VDI 2230 dated 2003.

– WARNING: High Temperature Hazard

During and shortly after operation of the pump the housing, control valves and especially solenoids can be extremely hot; avoidclose contact for risk of severe burns!

ContentsOrdering code EP - Electro-hydraulic control with proportional solenoid Technical data and circuit schematic Pressure control EPA with pressure control for port A only EPGA with remote pressure control in port A only EPB with pressure control in port B only EPGB with remote pressure control in port B only EPD with pressure control in both ports A and B EPG with remote pressure control in both ports A and B Unit dimensions EP Unit dimensions EPA / EPGA Unit dimensions EPB / EPGB Unit dimensions EPD / EPG Type of connector Safety information

Electro-hydraulic control with proportional solenoid EP...EP - Electro-hydraulic control with proportional solenoid The EP control adjusts the pump displacement proportional to the

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