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RE 30 021/03.

97

Electronic control system


for the closed loop control of
variable displacement axial piston pumps
type A4VS with HS3 or HS control

RE
30 021/03.97
Replaces: 11.95

H/C 4489/94

The HS(3) control is used for the electro-hydraulic control of


swivel angle and pressure as well as the power limitation of the
variable displacement axial piston pumps.
The HS3 control and closed loop system comprises of the
following sub-assemblies:
Axial piston pump type A4VSHS3 with built-on STW 0070/
STW 0073 or STW 0048/ proportional valve and
inductive position transducers for the acquisition of swivel
angle and valve position (for technical data and ordering
details see RE 92 050 for open circuits, RE 92 100 for for
closed circuits as well as RE 92 076)
Pressure transducers HM14 or HM15 for acquisition of the
system pressure
Amplifier card VT 12 350 for the realisation of all necessary
electrical functions for the HS3 control
Control box BB-3 (VT 12 321, see RE 29 798), control field
BF-1 (VT 12 323, see RE 29 794) or PC programme
BODIV (SYS-DigVen-BODIV-01, see RE 29 899)

The HS control and closed loop control system comprises of


the following sub-assemblies:
Axial piston pump type A4VSHS with built-on 4WS2EM 10
servo valve and inductive position tranducers for the
acquisition of swivel angle and valve position (for technical
data and ordering details see RE 92 050 for open circuits,
RE 92 100 for closed circuits as well as RE 92 076)
Pressure transducers HM14 or HM15 for acquisition of the
system pressure
Amplifier card VT-VAD-2 for the realisation of all necessary
electrical functions for the HS control
Control box BB-3 (VT 12 321, see RE 29 798), control feild
BF-1 (VT 12 323, see RE 29 794) or PC programme
BODIV (SYS-DigVen-BODIV-01, see RE 29 899)

Overview of contents
Contents
Functional description, section

Page
2

HS3 control circuit variations


A4VSO open circuit
A4VSH semi closed circuit
A4VSG closed circuit

3
3
4

Technical data, electrical


Closed loop circuit quality

5
6

Contents
Static characteristic curves
Transiant function
Amplifier VT 12 350

Page
6
6

Amplifier VT-VAD-2

7 to 11
12 to 17

Pressure transducers HM 14 and HM 15


Communication with the amplifier card

18 to 19
20

1/20

RE 30 021/03.97

Functional description, section


The closed loop swivel angle and pressure control as well as the
power limitaion of the variable displacement pump A4VS... is
carried out with an electrically controlled servo or proportional
valve (1). This valve determines the position of the adjustment
piston (2) via the swash plate of the pump (3).
With a non-rotating pump and pressure less adjustment system
as well as with the enable not given the swash plate is kept in the
swivel angle position zero via the spring centering.
The control electronics consists of a swivel angle, pressure and
valve controller as well as a power limiter. The position of the
swash plate is aquired with an inductive position transducer (4)
The pressure actual value is obtained by a pressure transducer.
Both actual values are supplied to the controller and are
connected via the software. The actual output power value is
derived from the product of actual pressure value and actual
swivel angle value. The controller software ensures that,
through the minimum value generator, the controller
corresponding to the working point is active.

2/20

For the HS3 control a proportional valve with electrical feedback


is used as the pilot control, for the HS control a servo valve with
mechanical feedback is used.
In a static condition, i.e. the swivel angle command value is the
same as the swivel angle actual value, power command value
is the same as the power actual value or the pressure command
value is the same as the actual pressure value, then the control
spool of the valve is in the centre position.
If a higher controller, e.g. requires that the swivel angle is to be
increased (this relates to an increase in flow) then the valve
spool has to be moved away from its centre position until the
swivel angle has reached the required angle.
The sectional drawing shows the A4VS... variable displacement
pump with the HS3 control; the proportional valve (1) is
controlled via the VT 12 350 amplifier card.

RE 30 021/03.97
021/11.94

Circuit variations for the HS3 control


A4VSO open circuit (see RE 92 050 and RE 92 076-HS3)

Users

u
p
i

b
B

A
Sp

VT 12 350

Rkv
B1 B

MB

u
Command
values

R4 R3 R2

MS

K1

K2

R5 R6 R7

R(L)

A4VSH semi closed circuit (see RE 92 110 and RE 92 076-HS3)

p
i

u
B

SB SA

b
B

VT 12 350
MA

MB

Sp
Rkv
P

Command
values

U
s

R4 R3 R2

K3

K2

R(L)

R5 R6 R7

3/20

RE 30 021/03.97

Circuit variations for the HS3 control (continued)


A4VSG closed circuit (see RE 92 100-HS3K)

1 pressure sensor via shuttle


valve or 2 pressure sensors

p
i
p
i
B

u
VT 12 350

Msp

b
B

MA

MB

Command
values
Sp
Rkv

U
s

R4 R3 R2

Note:
The pump type A4VSG without short circuit valve (1)
swivels, with a de-energised valve and applied adjuster
pressure, to the right hand swivel angle (Qmax).
For pressure control on both sides and for unmistakable
identification of the pressure side, two pressure transducers
are recommended.

4/20

K3

K2

R(L)

R5 R6 R7

RE 30 021/03.97

Technical data, electrical (for applications outside these parameters, please consult us!)
Valves STW 0070/STW 0073 for HS3 control (pump nominal sizes 40 to 355)
Imax

Power consumption

Control current
Solenoid coil resistance: cold value at 20 C
max. warm value

R
R

2.7 A
approx. 1.45 A
2
3

Duty: with amplifier in closed loop control mode of operation


proportional solenoid at Imax

100 %
60 % at UB = 24 V

Electrical connection

plug-in connector to DIN 43 650 - AFZ-Pg11

Protection to DIN 40 050

IP 65

Position transducer for valves STW 0070/STW 0073

5 kHz

between connections 1 and 2 R


between connections 3 and 4 R

113
101

Carrier frequency
Coil resistance (at 20 C):
Electrical connection

component socket GM 209

Plug connection protection to DIN 40 050

IP 65

Valve STW 0048/ for HS3 control (pump nominal sizes 500 and 750)
Imax

Power consumption

Control current
Solenoid coil resistance: cold value at 20 C
max. warm value

R
R

3.8 A
approx. 2 A
2
3

Duty: with amplifier in closed loop control mode of operation


proportional solenoid at Imax

100 %
80 % at UB = 24 V

Electrical connection

plug connection Amphenol C164-639F-5S

Protection to DIN 40 050

IP 65

Position transducer for valve STW 0048/

5 kHz

between connections 1 and 2 R


between connections 3 and 4 R

113
101

Carrier frequency
Coil resistance (at 20 C):
Electrical connection

plug connection ITT Canon CA 120 001-10

Plug connector protection to DIN 40 050

IP 65

Notes on the HS3 control:


The proportional valves STW 0070 (up to size 355) and STW 0048/AV (sizes 500 and 750)
relate to the pump drive direction "clockwise", i.e. with a de-energised valve the pump swivels
to = 0 with the A4VSO version or = 100 % with the A4VSG version.
If the pump is to be driven with a "anti-clockwise" hand direction of rotation, then the proportional
valves STW 0073 (up to size 355) or STW 0048/BV (sizes 500 and 750) are to be used.

Servo valve 4WS2EM 10 for HS control (for all nominal sizes of pumps)
Imax

Power consumption
Control current
Coil resistance per coil

60 mA

0 mA

40

Electrical connection

component socket 14S-2P

Protection to DIN 40 050

IP 65

Swivel angle transducer


f

Carrier frequency
Coil resistance (at 20 C):

between connections 1 and 2 R


R
between connections 2 and
between connections 1 and
R

5 kHz
32
46
32

Electrical connection

plug connection to DIN 43 650 - BFZ-Pg9

Plug connection protection to DIN 40 050

IP 65

5/20

021/03.97
RE 30 021/11.94

Quality of control circuit

Swivel angle control

Pressure control

Linearity tolerance

1.0 %

1.5 %

Temperature error

0.5 %/10 K

0.5 %/10 K

Hysteresis

0.2 %

0.2 %

Repeatability accuracy

0.2 %

0.2 %

Static characteristic curves


= 100 % output power
command

Flow
command
(com)

Flow in %

Output
power
command

Pressure
command

Operating pressure in bar

Transient function with swivel angle command value jump

Example size 250 adjustment pressure p = 125 bar

100

Actual swivel angle value in %

Actual swivel angle value in %

100
80

80

60

60

40

40

20

20

50

100

Time in ms

6/20

150

200

50

100

Time in ms

150

200

RE 30 021/03.97

Electronic amplifier VT 12 350, series 3X


The digital control amplifier VT 12 350 is used for the contol of
swivel angle and pressure of the axial piston units A4VS...HS3.
Additionally, with appropriate command value inputs the power
can be limited.
A fast response proportional control valve is used as the
adjustment element for the control.
Parametering of the amplifier is carried out via a serial interface.
The application specific data can be accurately reproduced and
is protected against unintentional or unauthorised adjustment.

Features:
Use of a powerful micro-controller
Digital inputs for the call-up of pre-set parameters
Ramp times for command values for swivel angle and
pressure
Analogue inputs for command and actual values
Enable input and collective error output
Oscillators/demodulators for two inductive measuring
systems
Pulsed, current controlled output stage
Switched mode power supply for the internal supply voltages
Function indication via LEDs
Measuring sockets for acutal values
Standardised terminal strip connection
Serial interface
Nominal size selection (40 to 750) and parametering via
control box BB-3 (VT 12 321, see RE 29 795) or
operating field BF-1 (VT 12 323, see RE 29 794) or
PC programme BODIV (SYS-DigVen BODIV-01, see RE 29 899)

H/A 4365/94

VT 12 350-3X/...

Suitable card holders are:


19 inch rack VT 19 101, VT 19 102, VT 19 103 and VT 19
110 (see RE 29 768)
Enclosed card holder VT 12 302 (see RE 30 102)
Open card holder VT 3002 (see RE 29 928)
only suitable for fitting into switching cabinets !

Technical data (for applications outside these parameters, please consult us!)
UB
uB (t)max
uB(t)min

Operating voltage
upper limiting value
lower limiting value
Power consumption
Nominal resistance solenoid (20 C)

Imax

4A

Oscillator frequency (position transducer, valve spool, swivel angle) f


Inputs:
Command value swivel angle (differential input)
Command value pressure (differential input)
Actual value pressure
or
Power input (p )com. (differential input)
Controller enable, ramp enable, tipp
Outputs:
Solenoid current
Actual values, valve spool position and swivel angle
Actual value pressure
Error messages (relay contact open)
Auxiliary voltages
Switching output 1, 2
Fuse (internal)

24 VDC + 40 % 10 %
35 V
21 V

Ue
Ue
Ue
Ie
Ue
U
I max
Ua
Ua
Ua
U
U
IS

approx. 5 kHz
10 V (Re= 20 k)
0 to 10 V (Re= 20 k)
0 to 10 V (Re= 20 k); only for 1 pressure sensor
4 to 20 mA (Re= 100 )
0 to 10 V (Re= 20 k)
log 0 = 0 to 2 V; log 1 = 15 V to UB
3.8 A
10 V
0 to 10 V
max. 100 mA with 24 V
15 V 3 %; 25 mA
+ 24 V; max. 50 mA (short circuit protected)
4AT

Type of connection

64-pin blade connector, DIN 41 612, type G

Card dimensions

Eurocard 100 x 160 mm, DIN 41 494

Front plate dimensions:


Height
Width printed circuit board side
Width component side

3 HE (128.4 mm)
1 TE (5.08 mm)
7 TE

0 to + 50 C

Storage temperature range

20 to + 70 C

Weight

0.3 kg

Permissible ambient temperature range

7/20

start

d12

Pressure actual A

A/D3
4
Com. call-up 1
Com. call-up 2
Com. call-up 4
Com. call-up 8
Com. valid

Pressure actual B

d2
d4
d6
d8
d10

A/D4
Command
value callup

b10

I
8

GND

GND

Minimum
value
generator

A/D6

5
A

A/D2

z20

Valve
controller

6
D

U
I

JP

A/D5
MUX

0V

z32

1 Power supply
2 Serial interface
(MDSM socket)
3 Programme and
parameter memory

error
UB

Memory

K1

power

Level adjustment
Differential amplifier
Current controlled output stage
Evaluation electronics for
position measuring system

+ USS

d24

USS

d28
d22

4
5
6
7

z4

d32

D/A1

Micro-controller

DC
DC

p 11b

11(C)
41(D)
31(E)
21(E)

1
2

9
1 Valid for sizes 40 to 355
( ) Valid for sizes 500 and
750
10

7
3

RS485

z30

z28
z26
z24

RS485
+ UB

z2

z18
z16
z14
z12

A/D7

pB

Proportional
valve

1
Valve
actual

Swivel angle actual

f26
RS 485 ()
f28
RS 485 (+)

D/A0

2
JP

z10

Power
calculation

select1
select2
select4
select8

b22
b24

pA

b28 Pressure actual value (p : 0 to 10 V)


act
b26 Swivel angle actual value ( : 10V)
act
b30 Valve actual value ( 10 V)

Minimum
value
generator

b18
Power com. +
value
b20
Pcom: 0 to 10 V

Swivel
angle
controller

I
b6
b8

11a

b2
b4

A/D1

Swivel angle com. + b14


value
b16
com: 10 V

System earth

Pressure
actual

Pressure
controller

Press. com. value +


pcom: 0 to 10 V b12

4 JP

UB

8 Evaluation electronics for pressure


transducer
9 Inductive position measuring system
(control valve)
10 Inductive position measuring system
(pump)

Test output ( 10 V)
+ 15 V (25 mA)
15 V (25 mA)
Fault message contact 1
(max. 100 mA an 24 V)

d26

Fault message contact 2

11a Pressure sensor(s) current interface


or
11b Pressure sensor voltage interface
(only for 1 pressure sensor)

RE 30 021/03.97

Control
logic

4
Ramp

d20 Switch output 1


(loadable up to 50 mA)
b32
Switch output 2
b6 (loadable up to 50 mA)
b8
z10
11a
b22
I
b24
p

Electronic amplifier VT 12 350, series 3X

Enable

Block circuit diagram / terminal connection

8/20

4
d18

RE 30 021/03.97

Electronic amplifier type VT 12 350, series 3X


Functional description
The amplifier is designed as a double-sided printed circuit card
in Euro-format 100 x 160 mm. The assembly has a switched
mode power supply [1], which supplies the internally required
voltages.
A micro-processor that controls the entire sequence and
provides the functions of the controller forms the central unit of
the amplifier. Amplifier specific data (configuration, command
values, parameters) are stored in a non-volatile EEPROM [3].
Four binary coded digital inputs are used for the call-up of
parameter sets (command values) from the memory, in which a
maximum of 16 sets can be stored. A call-up activates a
command value for the swivel angle, the pressure and the power
limitation as well as the ramp times for swivel angle and
pressure.
Further control inputs have the following functions:
"Com. valid": Enable of the parameter set that has been
activated by the actual call-up and blocking of
the process control (H-active)
"Ramp":
Activation of the ramp generator (H-active)
"Enable":
Activation of the control
(L/H edge or H-active)
Note:
H-aktive = High active (level 15 V to UB)
L-aktive = Low active (level 0 V to 2 V)
L/H edge = LowHigh edge
The analogue command values for swivel angle, pressure and
the maximum power are applied via three differential inputs [5].
With a positive swivel angle command value the pump swivels
to the "left" (= flow direction S B). The digital call-up
command values are added to the analogue command values,
the sum of both of the command values passes via the relevant
ramp generator to the input of the controller.
The controller output signal controls, in relation to the command/
actual difference, the output stage [6] of the amplifier.
The position of the valve spool [9], the swivel angle of the
variable pump [10] and the system pressure [11] are measured
and passed to the closed loop circuit via the evaluation
electronics [7, 8]. For pressure control three different modes are
possible:
1 pressure sensor (optionally current [11a] or voltage
interface [11b], switch over is via jumper J1) for open
circuits or (semi) closed circuits via a shuttle valve.
The pressure side is determined by the swivel angle.
2 pressure sensors (only current interface [11a]) for
(semi) closed circuits.
The pressure sensor which is to be evaluated is
determined by the swivel angle.
Mooring operation (only current interface [11a]) for
closed circuits
The pressure control is activated dependent on the actual
pressure for sides A or B.
Both of the switching outputs are configured via the serial
interface. The following functions can be selected:
Pressure control active (H-level)
Power limitation active (H-level)
The test output (d32 or measuring socket 3) is also configured
via the serial interface. It is used to display the internal values.

Enable and fault messages


The control is activated by an L/H edge at the enable input. If
no command value call-up is activated then the digital call-up 0
is set.
The fault logic can recognise the following faults:
Cable break or short circuit in the valve actual value
acquisition
Cable break or short circuit in the swivel angle value
acquisition
Cable break at the pressure transducer (only with current
interface)
Short circuit in the solenoid lines
Control fault (control deviation between the swivel angle
command value and swivel angle actual value)
Missing enable
A fault is given as a collective fault (opened relay contact) and
displayed optically via the LED error on the front plate. The
LEDs select 1, 2, 4, 8 display a fault code in the case of a fault.
Programming and diagnostics
The selection of the pump nominal size and the pressure
sensors, the activation or deactivation of the leakage oil
correction and the sequence control as well as the configuration
of the switch outputs and test outputs are carried out via the
serial interface [2] on the front MDSM plug or via the blade
connector using the PC software BODIV (SYS-DIGVEN-BODIV01), the operating field BF-1 (VT 12323) or operating box
(VT 12321). For connection purposes the cable VT 12322,
additionally when using BODIV the interface converter
VT 12304, is required.
Display elements and measurement sockets
The front plate of the amplifier is fitted with measurement sockets
for the following analogue outputs:
Measurement socket 1: Valve spool position - actual value
(with STW 0070 100 % = 7.15 V;
with STW 0048 100 % = 10 V)
Measurement socket 2: Swivel angle - actual value (100 %
= 10 V)
Measurement socket 3: A configurable output (100 % = 10 V)
for: swivel angle command value
pressure command value
power command value
actual value swivel angle
actual pressure value (pump sides A and B)
actual power value
adjustment variable at the output stage
resulting swivel angle command value
(for master slave coupling)
Measurement socket 4: Actual pressure value (pump side B)
Measurement socket Ia: Solenoid current (1 V = 1 A)
Measurement socket Ib: Not allocated
The following conditions are displayed via LEDs:
LED power (green):
Internal power supply
LED error (red):
Fault message
LED start (yellow):
Amplifier card enable
LED select 1, 2, 4, 8 (yellow):
Current command value
call-up/fault code for an
active fault
[ ] = cross reference to block circuit diagram

9/20

RE 30 021/11.95
021/03.97

Electronic amplifier VT 12 350, series 3X


Pin allocation of the blade connector and MSDM sockets
Pin

Row z

Row b

Row d

Row f
(optional)

Solenoid a +

Actual value pressure + (voltage interface)

Command call-up 1

Solenoid a

Actual value pressure (voltage interface)

Command call-up 2

Actual value pressure (A) + (curr. interface) Command call-up 4

Actual value pressure (A) (curr. interface) Command call-up 8

10

Screen for pos. and press. transducers Command value pressure +

Command valid

(H-active)

12

Pos.transducer for valve

Command value pressure

Ramp

(H-active)

14

Pos. transducer for valve

Command value swivel angle +

16

Pos. transducer for valve

Command value swivel angle

18

Pos. transducer for valve

Command value power +

Enable

(L H)

20

System earth

Command value power

Switching output 1 (H-active, max. 50 mA)

22

Pos. transducer for pump

Actual value pressure (B) + (curr. interface) Error message contact 1 (max.100 mA an 24 V)

24

Pos. transducer for pump

Actual value pressure (B) (curr. interface) + 15 V, 25 mA

26

Pos. transducer for pump

Output actual swivel angle value ( 10 V) Error message contact 2 (max.100 mA an 24 V) RS 485 ()

28

Pos. transducer for pump

Output actual pressure value (0 to 10 V) 15 V, 25 mA

30

UB: + 24 V

Output actual valve value ( 10 V)

32

L0: 0 V

System
Switching output 2 (H-active, max. 50 mA) Output 10 V; measuring socket 3 refers earth

The relay contact for the error message is opened with an


active collective error.

Pin allocation of MDSM socket on front plate:

Pressure actual value:


1 pressure sensor current interface to b22/24 or
voltage interface to b2/4
2 pressure sensors pressure side B to b22/24; pressure side
A to b6/8 (both are only current
interfaces)
Note:

RS 485 (+)

+ UB
0 V (GND)
RS 485 ()

RS 485 (+)

Optionally a 48-pin terminal strip, DIN 41 612, type F


may be used as a connection strip when the RS485
signals are not required.

Setting elements (position and meaning)

Actual pressure sensor value on b22/24


1 2 3

Current
1 2 3

Voltage
JP1
1 2 3

JP3
1
2
3
4
5

JP2

Amplifier card address


1
2
3
4
5

Address 0

1
2
3
4
5

Address 1

Bus end resistors


closed with communication with only one
amplifier card or only on the amplifier
card furthest away from the master in a
bus system

10/20

1
2
3
4
5

Address 31

RE 30 021/03.97

Electronic amplifier VT 12 350, series 3X


Ordering details
VT 12 350 3X/ 0
Digital amplifier for the control of variable displacement
axial piston pumps with HS3 control
Series 30 to 39
(30 to 39: unchanged technical data and pin allocation)

*
Further details in clear text
0=

Transducer for swivel angle type IW9

= 3X

Note:
The connection cable for control box BB-3 (VT 12 321) or for
control field BF-1 (VT 12 323) must be ordered separately!
Ordering code: VT 12 322

Project / maintenance instructions / additional information


The amplifier card may only be unplugged or plugged in when the power is switched off!
Measurements at the card only to be carried out with instruments with Ri > 100 k!
Do not connect the inductive transducer with earth signs with the 0V supply voltage (L0) or earth!
Use relays with gold-plated contacts for switching analogue command values and digital call-ups (small voltages, small
currents)!
Always screen command and actual value lines; screen open on one side, connect to system earth on card side!
Recommendation: Up to 50 m long use cable type LiYCY 1.5 mm2 for solenoid lines, for transducer lines use screened
cable type LiYCY 0.5 mm2. For longer lengths, please consult us!
The distance to antenna lines, radio sources or radar systems must be at least 1 m!
Do not lay solenoid and signal lines near power lines!
The commissioning and programming of the amplifier is described in detail in the product description and setting instructions
RE 30 021-01-B.
Note:

Electrical signals (e.g. fault message signal) taken via the valve electronics must not be used to
switch off machine safety functions!
(Also see European standard regulations "Safety requirements of fluid technology systems and
components hydraulics", draft prEN 982!)

(Dimensions in mm)

RS 485
2
4
Ib
GND

8TE (40,3)

2
7

15

1
3
Ia
GND

89

power
start
error
select 1
select 2
select 4
select 8
100

3HE (128,4)

Unit dimensions

165
186

11/20

RE 30 021/03.97

Electronic amplifier VT-VAD-2, series 1X


The digital control amplifier VT-VAD-2 is used for the control of
swivel angle and the pressure control of A4VS...HS axial piston
pumps. With the relevant command values the power can
additionally be limited.
A servo valve is used as the adjustment element.
The parameterisation of the amplifier is via a serial interface. The
user specific data is exactly reproducible and is protected
against unintended or unauthorised changes.

Features:

Use of a powerful micro-controller


Digital inputs for calling-up pre-set parameters
Ramp times for swivel angle and pressure command values
Analogue inputs for command and actual values
Enable input and collective fault output
Oscillators/demodulators for an inductive measurement
system
Pulsed, current regulated output stage
Switched mode power supply for the internal supply
voltages
Function display via LEDs
Measurement sockets for the actual values
Standardised terminal strip allocation
Serial interface
Parametering via
control box BB-3 (VT 12 321, see RE 29 795) or
operating field field BF-1 (VT 12 323, see RE 29 794) or
PC programme BODIV (SYS-DigVen BODIV-01, see RE 29 899)

H/A 5496/96

VT-VAD-2-1X

Suitable card holders are:


19 inch rack VT 19 101, VT 19 102, VT 19 103 and VT 19
110 (see RE 29 768)
Enclosed card holder VT 12 302 (see RE 30 102)
Open card holder VT 3002 (see RE 29 928)
only suitable for use in switching cabinets!

Technical data (for applications outside the stated values, please consult us!)
UB
uB (t)max
uB(t)min

Operating values
upper limiting value
lower limiting value

Imax

Power consumption

Oscillator frequency (swivel angle transducer)


Inputs:
Swivel angle command value (differential input)
Pressure command value (differential input)
Actual pressure value
or
Power required (p )com. (differential input)
Controller enable, ramp enable
Outputs:
Solenoid current
Actual swivel angle value
Actual pressure value
Fault message (relay contact open)
Switch output 1, 2
Fuse (internal)

Ue
Ue
Ue
Ie
Ue
U
I max
Ua
Ua
Ua
U
IS

24 VDC + 40 % 10 %
35 V
21 V
450 mA
approx. 2.5 kHz
10 V (Re= 100 k)
0 to 10 V ( Re= 100 k)
0 to 10 V ( Re= 100 k); only for 1 pressure sensor
4 to 20 mA ( Re= 100 )
0 to 10 V ( Re= 100 k)
log 0 = 0 to 2 V; log 1 = 15 V to UB
60 mA
10 V
0 to 10 V
max. 100 mA an 24 V
+ 24 V; max. 50 mA (short circuit protected)
4AT

Connection type

48-pin blade connector, DIN 41 612, form F

Card dimension

Eurocard 100 x 160 mm, DIN 41 494

Front plate dimensions:


Height printed circuit board side
Width component side

1 TE (5.08 mm)
7 TE

Permissible ambient temperature

0 to + 50 C

Storage temperature

20 to + 70 C

Weight

0.3 kg

12/20

Control
logic

start

d12

Ramp

Pressure actual A

A/D3
4
Com. call-up 1
Com. call-up 2
Com. call-up 4
Com. call-up 8
Com. valid
+

Command
value
call-up

b10

b12

5
A

b14

b16

GND

5
A

Minimum
value
generator

GND

b28
Pressure actual value (pact.: 0 to 10 V)
b26 Swivel angle actual value ( : 10 V)
act.

A/D2

z20

JP
d28
RS 485 ()
d24
RS 485 (+)

Power
calculation

z6

z8

Swivel angle
actual

z4
z28

A/D5

JP

z26
z22
z24
z10

RS485

MUX
2

z30
+

d32

1 Valid for sizes 40 to 355


( ) Valid for sizes 500 and
750

2
IW9/IW18

Test output ( 10 V)

error
UB
d22
3
K1
Memory

power

4
5
6
7

Level adjustment
Differential amplifier
Current controlled output stage
Evaluation electronics for
positional measuring system

8
9

Evaluation electronics for


pressure transducer
Inductive position
measuring system
(pump)

Fault message contact 1

(max. 100 mA an 24 V)
d26 Fault message contact 2

10a Pressure sensor(s) current interface


or
10b Pressure sensor voltage interface
(only for 1 pressure sensor)

RE 30 021/03.97

13/20

1 Power supply
2 Serial interface
(MDSM socket)
3 Programme and
parameter memory

D/A1

Micro-controller

DC
DC

Servo valve

C1(A) D1(B)

(z32)

RS485
z32

z2

A1(C) B1(D)

Minmum
value
generator

Swivel
angle
controller

D/A0

select1
select2
select4
select8

0V

Pressure
controller

A/D6

Power com. +
value
b20
Pcom.: 0 to 10 V

+ UB

A/D1

b18

System earth

Pressure
actual

4 JP

A/D4

Press. com.
value
pcom.: 0 to 10 V
Swivel angle
com. vaue
com.. : 10 V

Pressure actual B

d2
d4
d6
d8
d10

Electronic amplifier VT-VAD-2, series 1X

Enable

d20 Active with activated pressure control


(loadable up to 50 mA)
UB
b32
Active with activated power
limitation
I
b6 (loadable up to 50 mA)
pA
b6
b8
b8
10a
I
b22
pB
b22
I
b24
p
b24
10a
b2
U 10b
b4
p
z10

Block circuit diagram / terminal allocation

4
d18

RE 30 021/03.97

Electronic amplifier VT-VAD-2, series 1X


Functional description
The amplifier is designed as a double-sided printed circuit card
in Euro-format 100 x 160 mm fitted with a daughter board. The
basis board is the digital command value card VT-SWKD-1-1X
(see RE 30 121). With the daughter board VT-TAD-2-1X an
amplifier is obtained for the control of the
A4VS pump fitted with an HS control.
The assembly has a switched mode power supply [1], which
supplies the internally required voltages.
A micro-processor that controls the entire sequence and
provides the functions of the controller forms the central unit of
the amplifier. Amplifier specific data (configuration, command
values, parameters) are stored in a non-volatile EEPROM [3].
Four binary coded digital inputs are used for the call-up of
parameter sets (command values) from the memory, in which a
maximum of 16 sets can be stored. A call-up activates a
command value for the swivel angle, the pressure and the power
limitation as well as the ramp times for swivel angle and
pressure.
Further control inputs have the following functions:
"Com. valid": Enable of the parameter set that has been
activated by the actual call-up and blocking of
the process control (H-active)
"Ramp":
Activation of the ramp generator (H-active)
"Enable":
Activation of the control
(L/H edge or H-active)
Note:
H-active = High active (level 15 V to UB)
L-active = Low active (level 0 V to 2 V)
L/H edge = LowHigh edge
The analogue command values for swivel angle, pressure and
the maximum power are applied via three differential inputs [5].
With a positive swivel angle command value the pump swivels
to the "left" (= flow direction S B). The digital call-up
command values are added to the analogue command values,
the sum of both of the command values passes via the relevant
ramp generator to the input of the controller.
The controller output signal controls, in relation to the command/
actual difference, the output stage [6] of the amplifier.
The swivel angle position of the variable displacement pump [9]
and the system pressure [10] are measured and then passed to
the closed loop circuit via the evaluation electronics [7, 8]. For
pressure control three different modes are possible:
1 pressure sensor (optionally current [10a] or voltage
interface [10b], switch over is via jumper J1) for open
circuits or (semi) closed circuits via a shuttle valve.
The pressure side is determined by the swivel angle.
2 pressure sensors (only current interface [10a]) for
(semi) closed circuits.
The pressure sensor which is to be evaluated is
determined by the swivel angle.
Mooring operation (only current interface [10a]) for
closed circuits
The pressure control is activated dependent on the actual
pressure for sides A or B.
The two switch outputs show "pressure controller active" or
"power limitation active".
The test output (d32 or measuring socket 3) are also configured
via the serial interface. It is used to display the internal values.

Sequence control
As an option, it is possible to activate a sequence control that
independently starts digital command value call-ups to
programmable times in a programmable sequence. The signal
"com. valid" has to be inactive (L-level) for this, otherwise the
command value call-ups via the inputs "com. call-ups 1, 2, 4, 8"
have priority.
Enable and fault messages
Dependent on the configuration of the enable input the control
is activated by either a L/H edge or a H-level at the enable input.
If no command value call-ups are active then the digital call-up 0
is set.
The fault logic can recognise the following faults:
Cable break or short circuit in the swivel angle actual value
acquisition
Cable break at the pressure transducer (only current interface)
Control fault (i.e. control deviation between the swivel
angle command value and swivel angle actual value)
Missing enable
A fault is issued as a collective fault (opened relay contact) and
displayed optically via the LED error on the front plate. The
LEDs select 1, 2, 4, 8 show a fault code in the case of a fault.
Programming and diagnostics
The selection of the pump nominal size and the pressure
sensors, the activation or deactivation of the leakage oil
correction and the sequence control as well as the configuration
of the switch outputs and test outputs are carried out via the
serial interface [2] on the front MDSM plug or via the blade
connector using the PC software BODIV (SYS-DIGVEN-BODIV01), the operating field BF-1 (VT 12323) or operating box
(VT 12321). For connection purposes the cable VT 12322,
additionally when using BODIV the interface converter
VT 12304, is required.
Display elements and measurement sockets
The front plate of the amplifier is fitted with measurement sockets
for the following analogue outputs:
Measurement socket 1: Not allocated
Measurement socket 2: Swivel angle - actual value (100 %
= 10 V)
Measurement socket 3: A configurable output (100 % = 10 V)
for: swivel angle command value
pressure command value
power command value
swivel angle actual value
actual pressure value (pump sides A and B)
actual power value
adjustment variable at the output stage
Measurement socket 4: Actual pressure value (pump side B)
Measurement socket Ia: Not allocated (1 V = 1 A)
Measurement socket Ib: Not allocated
The following conditions are displayed via LED's:
LED power (green):
Internal power supply
LED error (red):
Fault message
LED start (yellow):
Amplifier card enable
LED select 1, 2, 4, 8 (yellow):
Actual command value
call-up/fault code for an
active fault
[ ] = cross reference to block circuit diagram

14/20

RE 30 021/03.97

Electronic amplifier VT-VAD-2, series 1X


Pin allocation of blade connector and MSDM sockets
Pin
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

Row z

Row b

Row d

Coil

Actual value pressure + (voltage interface)


Actual value pressure (voltage interface)
Actual value pressure (A) + (curr. interface)

Command call-up 1
Command call-up 2
Command call-up 4

Actual value pressure (A) (curr. interface)


Command value pressure +
Command value pressure
Command value swivel angle +

Command call-up 8
Command valid (H-active)
Ramp
(H-active)

Screen for pos. and press. transducers

System earth

Command value swivel angle


Command value power +
Command value power

Enable
(L H or H-active)
Switching output 1(H-active, max. 50 mA)

Pos. transducer for pump


Pos. transducer for pump
Pos. transducer for pump

Actual value pressure (B) + (curr. interface)


Actual value pressure (B) (curr. interface)
Output actual swivel angle value ( 10 V)

Error message contact 1 (max.100 mA an 24 V)


RS 485 (+)
Error message contact 2 (max.100 mA an 24 V)

Pos. transducer for pump


UB: + 24 V
L0: 0 V

Output actual pressure value (0 to 10 V)

RS 485 ()

Switching output 2 (H-active, max. 50 mA)

Output 10 V; measuring socket 3 refers

The relay contact for the error message is opened with an


active collective error.

Pin allocation of MDSM socket on front plate:

Pressure actual value:


1 pressure sensor current interface to b22/24 or
voltage interface to b2/4
2 pressure sensors pressure side B to b22/24; pressure side
A to b6/8 (both are only current
interfaces)

+ UB
0 V (GND)
RS 485 ()

RS 485 (+)

Setting elements (position and meaning)


Sensitivity adjustment for swivel
angle transducer
R1

Setting for the VT-VAD-2


Do not change!

Setting for the VT-VAD-2


Do not change!

J1 J2
J3 J4

Pressure transducer configuration pB


Sensor p B voltage b2/b4

Address card
Address 0
Address 1

Address 15

Sensor p B current b22/b24

Bus end positions


RS 485
Closed on an
individual card or
the last card in a
bus system,
otherwise open.

Explanation:
1
2
3

Jumper open
Address 31

Jumper closed

15/20

RE 30 021/03.97

Electronic amplifier VT-VAD-2, series 1X


Ordering details
When ordering a complete amplifier

VTVAD 2 1X/ V0 / 0

Digital amplifier for controlling


axial piston pumps

Further details in clear text


0=

Basic unit

Amplifier for the A4VS variable displacement pump with HS control


V0 =
Series 10 to 19
(10 to 19: unchanged technical data and pin allocation)

Basic unit

= 1X

When ordering two individual components


1. Basic board:

VTSWKD 1 1X/ V0 / 0

Digital command value card

Further details in clear text

Series 10 to 19
(10 to 19: unchanged technical data and pin allocation)

= 1X

0=

Basic unit

V0 =

Basic unit

2. Daughter board:

VTTAD 2 1X/ V0 / 0

*
Further details in clear text

Daughter board for VT-VAD digital amplifier


0=

Amplifier for the A4VS variable displacement pump with HS control


Series 10 to 19
(10 to 19: unchanged technical data and pin allocation)

= 1X

V0 =

Basic unit
Basic unit

Attention! When fitting the daughter board onto the basic board, care must be taken to ensure that they are correctly
positioned and located otherwise both boards will be destroyed. After completion the relevant combination should
be entered on the lable that is on the reverse side of the amplifier card. This is necessary to clearly identifiy the
amplifier card.
When switching on for the first time after being plugged together the data memory (EEPROM) is reprogrammed,
this takes approx. 1.5 min. and is indicated by the blinking of LED's "select 1, 2, 4, 8". Communication with the
card during this time is not possible.

16/20

RE 30 021/03.97

Electronic amplifier VT-VAD-2, series 1X


Project / maintenance instructions / additional information
The amplifier card may only be unplugged or plugged in when the power is switched off!
Measurements at the card only to be carried out with instruments with Ri > 100 k!
For switching command values, use relays with gold-plated contacts (small voltages, small currents)!
Always screen command value lines; connect the screen to system earth on card side (z10), other end open
(danger of earth loops)!
Recommendations:
Also screen solenoid cables!
For solenoid cables up to 50 m long use cable type LiYCY 1.5 mm 2. For longer lengths, please
consult us!
The distance to antenna lines, radio sources or radar systems must be at least 1 m!
Do not lay solenoid and signal lines near power lines!
Due to the loading current of the smoothing capaciter on the card, back-up fuses must have a slow blowing characteristic!
The commissioning and programming of the amplifier is described in detail in the product description and setting instructions
RE 30 021-01-B.
Attention: When using the differential inputs both inputs must always be simultaneously be switched on or off!
If the command value inputs are not used then these are to be short circuited!
Note:

Electrical signals (e.g. fault message signals) taken via the valve electronics must not be used to
switch off machine safety functions!
(Also see European standard regulations "Safety requirements of fluid technology systems and
components hydraulics", draft prEN 982!)

Unit dimensions

(Dimensions in mm)

122

70

89

select 1
select 2
select 4
select 8

100

RS485

1
2
4
3
Ib
Ia
GND GND

VTD
12

8TE (40,3)
7

141,5

9,5

165
195,5

11,5

3HE (128,4)

power
start
error

17/20

RE 30 021/11.94
021/03.97

Pressure transducers HM 14 and HM 15


The pressure transducers HM 14 and HM 15 are used for the
measuring of pressures as well as transformation of measuring
values into electrical signal values. Because of their accuracy
and the temperature stability they are suitable for the use in
control circuits. Their EMC characteristics also permit the use in
critical applications.
Because of the standard output signal the pressure transducers
HM 14 (voltage output) and HM 15 (current output) can universally
be used in hydraulics.

Features:

Sensor in thin film technology


Evaluation electronics in SMD technology
Accuracy class < 0.5 %
Measuring ranges 10 to 600 bar
Connection thread to DIN 3852
Parts in contact with fluid made of stainless steel
Compact design

H/A 3695/93

Pressure transducer HM 14 and reducr piece ZBM 01

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

HM 14

Input values
Supply voltage
Measuring range (in bar)
Overload protection (in bar)
Burst pressure (in bar)
Output values
Output signal
Temperature compensation:
Zero point
Range
Linearity tolerance
Hysteresis
Repeatability accuracy
Rise time
Long time drift (6 months)
Ambient conditions
Nominal temperature range
Operating temperature range
Storage temperature range
Medium temperature range
EMC tolerance to IEC 801-4
Shock
Vibration resistance to IEC 68-2-6 (at 10 to 500 Hz)
Insulation to DIN 40 050

U
p
p
p

1)

18/20

Referring to complete measuring range


Preferred type

12 to 15 V
50
100
200
200
500
500

U = 0 to 10 V (4 track)

Mechanical values
Pressure port
Electronic connection
Life expectancy
Weight

10
20
100

HM 15

200
400
1000

315
600
1000

10 to 30 V
450
600
800
900
2000
2000

I = 4 to 20 mA (2 track)

type 0.08 %/10 K; max. 0.15%/10 K


type 0.08 %/10 K; max. 0.15 %/10 K
type 0.1 % 1); max. 0.3 % 1); from 100 bar: max. 0.2 % 1)
type 0.05 % 1); max. 0.1 % 1)
0.05 % 1)
0.5 ms
0.1 % 1)
25 to + 85 C
40 to + 85 C
40 to + 125 C
40 to + 100 C
degree 3
500 g / 1 ms
20 g
IP 65
G 1/4 A external thread to DIN 3852; soft seal ring
option: reduction piece for fitting to G1/2 (must be ordered separately)
4-pin MIL plug
10 Mio. load changes
approx. 0.18 kg

RE 30 021/03.97

Pressure transducers HM 14 and HM 15


Pin allocation HM 14
VT 12 350-3X
A

d24

+ 15 V

HM 14

Signal 0 to + 10 V

b2

0V

b4

C
D

+ 15 V

+ 15 V

Pressure transducer

VT-VAD-2-1X

Actual press. (+)

Signal

b2

0V

b4

Actual press. ()
d28

15 V

z32

Act. press. (+)


Act. press. ()

15 V

15 V

External
15V supply
e.g. with a VT 11006
(see RE 29 729)

0V

Pin allocation HM 15
VT 12 350-3X and VT-VAD-2-1X

+U

free

Pressure trasducer
B

HM 15

b22 Actual pressure (+)

100

b24 Actual pressure ()

free

z32
0V

Ordering details
HM

1X /

Hydraulic measuring device

Further details in clear text

Pressure transducer with:


Voltage output 0 to 10 V
Current output 4 to 20 mA

= 14
= 15

10
50
100
200
315
450
600

Series 10 to 19
= 1X
(10 to 19: unchanged technical data and terminal connection)

Measuring ranges:
up to 10 bar
up to 50 bar
up to 100 bar
up to 200 bar
up to 315 bar
up to 450 bar
up to 600 bar

=
=
=
=
=
=
=

preferred type

Unit dimensions HM 14 and HM 15

(Dimensions in mm)
3

12

51

27

G 1/A A

84,5

13

27 A/F

1 Pressure port G 1/4 form A to DIN 3852 part 2 with soft seal ring
2 Electrical connection via 4-pin plug connector mating plug included within the scope of supply
Ordering details of mating plug: PT06E 8-4SW(SR) or MS3116F8-4SW
3 Minimum installation length

19/20

RE 30 021/03.97

Communication with the amplifier card


Parametering, configuration and diagnosis is carried out via a
serial interface.

VT 12 350 - 3X
Amplifier card 1
JP3.1
JP3.2
BB-3

Control box BB-3


VT 12 321

f26
f28

BF-1

Control field BF-1


VT 12 323
RS

Dialogue description
see RE 29 798-01-B

485

VT-VAD-2-1X
Amplifier card n
Connection
cable
VT 12 322

JP1
JP2

d24

48

15-pin
HD-SUB socket

RS

RS232/485 Convertor
VT 12 304

d28

9-pin
D-SUB
socket

Warning!

The bus end resistors may only be


present on the amplifier card furthest
away (JP3.1 and JP3.2 or JP1 and
JP2 closed), otherwise the driver
components may be destroyed.

RS

232

15-pin
HD-SUB socket

BODIV
COM 1 to 4

PC programme BODIV
(SYS-DigVen-BODIV-01)
programme description
see RE 29 899-B

A maximum of 32 amplifier cards may be controlled with the


control units BB-3 (VT 12 321), BF-1 (VT 12 323) or with the PC
and the RS232/485 cable converter (VT 12 304). The amplifier
cards are to be connected in parallel via the connections f26/f28
(for VT 12350) or d24/d28 (for VT-VAD-2). The address of each
amplifier card is set via the DIL switches.

Mannesmann Rexroth GmbH


D-97813 Lohr am Main
Jahnstrae 3-5 D-97816 Lohr am Main
Telefon 0 93 52 / 18-0 Telefax 0 93 52 / 18-10 40
Telex 6 89 418-0

20/20

Mannesmann Rexroth Limited


Cromwell Road, St. Neots,
Huntingdon, Cambs. PE19 2ES
Tel: (01480) 476041
Fax: (01480) 219052

The specified data is for product description purposes only and may not be deemed to be
guaranteed unless expressly confirmed in the contract. All rights reserved Subject to revision