Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Electro-hydraulic RE 92 088/08.04 1/12

Additional to. RE 92 050

Control system DFE1

Technical data sheet

Size 125...355
Series 30
Nominal pressure 350 bar
Peak pressure 400 bar
open circuit

Contents Features

Type code - standard range 2

The DFE1 control system is used for the electro-hydraulic
Components 4 control of
Functional description 5 – Pressure
DFE1 6 – Flow
DFE1Y 7 – Power (optional)
DFE1Z 8
The control system is used together with the axial piston pump
Transition at jump in command input for swivel angle 9 A4VSO in sizes 125, 180, 250, and 355 acc. to RE 92050.
Quality of control 10
Unit dimensions 10 350
Safety information 11 p
Operating press. p [bar]

α
0
0 100
Swivel angle α [%]
2/12 Bosch Rexroth AG | Industrial Hydraulics Electro-hydraulic Control system DFE1 | RE 92 088/08.04

Type code - standard range

Fluid/Version 125 180 250 355
Mineral oil (Without prefix)
HF-Fluids on request E
High speed - - H
Axial piston unit
Swashpate design, variable, industrial use 350 bar, peak pressure 400 bar A4VS
Mode of operation
Pump, open circuit O
Size
Displacement Vgmax [cm3] 125 180 250 355
Type of control
Electronic pressure-flow control
internal supply of control oil, swivel range -100% to +100% DFE1
external supply of control oil, swivel range -100% bis +100% DFE1Y
external supply of control oil, swivel range 0 bis +100% DFE1Z
Series
30
Direction of rotation
looking at shaft end clockwise R
c. clockwise L
Seals
NBR Nitrile-Rubber to DIN ISO 1629 (shaft seal in FKM) P
FKM Fluoro-Rubber to DIN ISO 1629 V
Shaft end
Cyl. with key DIN 6885 P
Splined end DIN 5480 Z

available
in preperation
- not available
 RE 92 088/08.04 | Electro-hydraulic Control system DFE1 Industrial Hydraulics | Bosch Rexroth AG 3/12

A4VS O / 30 - B
Fluid/Version
Axial piston unit
Mode of operation
Size
Type of control
Series
Direction of rotation
Seals
Shaft end

Mounting flange
ISO 4-hole B
Port for service lines
Pressure port B, Inlet port S: SAE on side 90° offset, fixing screws metric 13
Pressure port B, Inlet port S: SAE on side 90° offset, fixing screws metric
2. Press. portB1 opposite B-, on delivery closed with blanking plate 25
Through drive 125 180 250 355
Without through drive N00
Flange ISO Coupler for splined shaft DIN 5480 Seal
125, 4-hole 32x2x30x14x9g radial K31
140, 4-hole 40x2x30x18x9g radial K33
160, 4-hole 50x2x30x24x9g radial K34
224, 4-hole 60x2x30x28x9g radial - - K35
224, 4-hole 70x3x30x22x9g radial - - - K77
Flange SAE J744 Coupler for splined shaft Seal
82-2 (A) 5/8 in (A) radial K01
82-2 (A) 3/4 in (A-B) radial K52
101-2 (B) 7/8 in (B) axial K02
101-2 (B) 7/8 in (B) radial K68
101-2 (B) 1in (B) radial K04
127-2 (C) 1 1/4 in (C) radial K07
127-2 (C) 1 1/2 in (C-C) axial K24
152-4 (D) 1 3/4 in (D) axial - K17
with through dr. shaft,without coupler,without adapter flange,closed with cover K99

Combination pumps

If a second Rexroth pump is to be factory mounted, then both type codes are to be connected wit a „+“ . Type code 1. Pump + Type
code 2. Pumpe

Example: A4VSO 250 DFE1/30R - PPB13K34 + A4VSO 125 DFE1/30R - PZB13N00

If an auxiliary pump is to be factory mounted , please contact us.

4/12 Bosch Rexroth AG | Industrial Hydraulics Electro-hydraulic Control system DFE1 | RE 92 088/08.04

Components
The controlsystem DFE1 comprises the following components: – Analog amplifier VT 5041-2X to RE 30 240 (please order
– Well proven high pressure axial piston pump A4VSO in separately)
swashplate designfor use in heavy duty industrial applications The system contains the following features:
– Proportional valve VT-DFP-A-2X for exact control with feed
back of valve spool position (see RE 29 016) – Pump combinations are posible
– Inductive displacement transducer for feedback of – Control pressure internal or external via pilot pump (see
swashplate angle page 7 and 8)
– Pressure transducer HM 12-1X for feedback of system – Fast decompression of trapped fluid by letting the pump go
pressure to RE 29 933 (optional, only required with over center as a standard (see page 6)
pressure and power control functions, please order
– Rotary group optimised for long life in standby operation
separately)

IVent

To system

αactual

Sactual pactual

Error signal Release

Prequired αrequired prequired

Machine control
RE 92 088/08.04 | Electro-hydraulic Control system DFE1 Industrial Hydraulics | Bosch Rexroth AG 5/12

Functional description
The power,pressure and displacement control of pump A4VSO- The necessary oil to operate the hydraulic control system can be
DFE1 is accomplished by means of an electro-proportional control supplied in two different ways:
valve (4). A current to the proportional valve results in an oil flow to
1. Internal (DFE1) from own pump outlet (page 6)
the pump’s control piston (2), which determines via the displacement
transducer (3) the swashplate angle (1) and thus the pump flow. 2. External (DFE1Y, DFE1Z) from separate system (page 7/8)

The proportional valve is controlled with amplifier card VT

With the pump in standstill, and the control system without pressure,
5041-2X. This card processes all control signals which are
the bias spring will push the pump to max. displacement (Vgmax).
necessary to operate pump A4VSO.DFE1 Standard are input
signals for pressure and swivel angle as well as an optional
Standby pressure (DFE1):
signal for power control. The actual value for pressure is picked
up by a pressure transducer. A displacement transducer picks
With a de-energized proportional valve and a closed pump
up the actual pump swivel angle. The amplifier card compares
outlet the pump will go to Vgmin - Standby pressure.In this
these actual values with the command inputs. A minimum value
condition the pressure level will reach 4 to 8 bar. The same
generator assures the activation of the appropriate controller.
applies also in case of an error signal or missing control
The output signal of this generator is used as the input signal
release.
to the proportional valve solenoid. In order to achieve a better
quality of control, the proportional valve operates as a
If the standby pressure of 4 to 8 bar is not desired, it is possible to
secundary control loop.
use type DFE1Y, or DFE1Z .

1 2

4
6/12 Bosch Rexroth AG | Industrial Hydraulics Electro-hydraulic Control system DFE1 | RE 92 088/08.04

DFE1
Control oil supply internal, Fail safe feature
Swivel range -100% to +100%
Below 4 to 8 bar the pump will stroke to larger displacement;
With DFE1 the control energy is taken out of the main pump an undesired operation with negative flow cannot occur.
flow. The min. pressure must be at least 4 to 8 bar. (see also
point „Standby pressure“on page 5 and „Fail safe feature“)
This min pressure is necessary for the control of flow, pressure 100
and power. Below this pressure, the pump tends to go to max. αist
displacement regardless of the input signals.

α [%]
0
time
As a special feature the pump is able to change the direction
-50
of flow.This capability to swivel over center enables a fast de-
compression of trapped oil volume. 240
p ist p ist

p [bar]
160 1
p soll p soll1
80
0
time

To system
Pressure transducer2)
P
I/U analog amplifier
Pressure command input 0 to 10V VT5041-2X/1
VT5041-2X/31)
Power command input1) 0V to 10V
System Flow command input ±10V
relief
Release
Error

U
S
Scope of supply

B1 B MB

S
U

U S MS M1 K1 K2 T R(L) M2

1)
optional, power limiting
2)
only needed with pressure resp. power control
RE 92 088/08.04 | Electro-hydraulic Control system DFE1 Industrial Hydraulics | Bosch Rexroth AG 7/12

DFE1Y
External supply of control oil,
Swivel range -100% to +100%

With DFE1Y the control energy has to be supplied externally, This control version features a reversal of the direction of flow,
eg. a gear pump. An automatic change-over to internal supply also at pressures below 4 to 8 bar. This option enables a fast
is accomplished by means of a shuttle valve. decompression of trapped oil volume by swiveling over center.

To system
Press. transducer2)
P
I/U
analog amplifier
Press. command input 0 to 10V VT5041-2X/1
Power command input1) 0 to 10V VT5041-2X/31)
System Flow command input ±10V
relief
Release
Error
0,2 bar3)
20 to 50 bar
Anti cavitation valve

U
S
Scope of supply

B1 B MB Z

S
U

U S MS K1 K2 T R(L) M

Caution!
– In the case of an externally supplied control system (Swivel – When an error is detected, the output stage switches off and
range ± 100%), the function, which swivels the pump to zero the external supply causes the pump to swivel towards the
stroke when the output stage of the control card is de- negative limit stop. Upon detection of an error message, it is
energized is inactive. essential that the machine control responds (e.g drive motor
of the pump must be switched off, external supply of the
– In the case of a de-energized output stage of the control card
control system must be interrupted).
(e.g. in case of an error), the external control pressure pushes
the variable pump's swashplate to the negative limit stop – The command values for pressure and flow must always be
(100% flow is delivered from the system to the tank). In order greater than zero (pcomm ≥ 3bar, α comm ≥ 5%), since, due to
to avoid cavitation the use of a checkvalve (anti cavitation drift or inaccurate control, there is no exact “zero“ pressure
valve with 0,2 bar spring) is required. or “zero“ swivel angle. Under unfavourable conditions,
smaller command values can cause cavitation.
1)
optional, Power limiting
2)
only needed with press. resp. power control
8/12 Bosch Rexroth AG | Industrial Hydraulics Electro-hydraulic Control system DFE1 | RE 92 088/08.04

DFE1Z
Control oil supply external, Qmin-limiting screw which prevents the unit from going over
swivel range 0 to 100% center.

Version DFE1Z has an input port for external supply of control Therefore, the option of fast decompression of trapped oil
flow, e.g. from a gear pump. The DFE1Z control offers a volume does not exist with this version.

To system

Press. transducer2)
P
I/U
analog amplifier
VT5041-2X/1
Press. command input 0 to 10V
VT5041-2X/31)
Power command input1) 0 to 10V

System Flow command input 0 to 10V

relief
Relaese

Error

20 to 50 bar

U
S
Scope of supply

B1 B MB Z

S
U

U S MS K1 K2 T R(L) M

1)
optional, power limiting
2)
only needed with press. resp. power control
RE 92 088/08.04 | Electro-hydraulic Control system DFE1 Industrial Hydraulics | Bosch Rexroth AG 9/12

Transition at jump in command input for swivel angle

Size 125, p = 100 bar

Swivel angle actual value [%]

100 100

80 80

60 60

40 40

20 20

0 50 100 150 200 0 50 100 150 200

time [ms] time [ms]

Size 180, p = 100 bar

Swivel angle actual value [%]

100 100

80 80

60 60

40 40

20 20

0 50 100 150 200 0 50 100 150 200

time [ms] time [ms]

Size 250, p = 100 bar

Swivel angle actual value [%]

100 100

80 80

60 60

40 40

20 20

0 50 100 150 200 0 50 100 150 200

time [ms] time [ms]

Size 355, p = 100 bar

Swivel angle actual valuet [%]

100 100

80 80

60 60

40 40

20 20

0 50 100 150 200 0 50 100 150 200

time [ms] time [ms]

10/12 Bosch Rexroth AG | Industrial Hydraulics Electro-hydraulic Control system DFE1 | RE 92 088/08.04

Quality of control
Swivel angle control Pressure control
Linearity tolerance < 1,0% < 1,5%
Hysteresis < 0,2% < 0,2%
Repeatibility < 0,2% < 0,2%
(The above values are only valid when using the appropriate components acc. to the ordering code )

Unit dimensions
Sizes 125 to 355 (Shown: size 125 in clockwise rotation)
A6 A6
A3 A5
A7
R(L)

Z, M1
M, M2
A2

A8
K2 K1
A1

MB MS
T
X S
A4

Size A1 A2 A3 A4 A5 A6 A7 A8
125 [mm] 121 298 250,5 376 147 177 50 209
180 [mm] 121 298 250,5 376 147 177 50 209
250 [mm] 154 345 310,5 438 212 179 55 259
355 [mm] 154 345 310,5 464 212 179 55 259

Ports 125 180 250 355

Z Control press. port M14x1,5 M14x1,5 M14x1,5 M14x1,5
1 1 1
B Pressure port [in] 1 /4 1 /4 1 /2 11/2
T Case drain M33x2 M33x2 M42x2 M42x2
MB Gauging port system pressure M14x1,5 M14x1,5 M14x1,5 M14x1,5
MS Gauging port inlet pressure M14x1,5 M14x1,5 M14x1,5 M14x1,5
S Inlet port [in] 21/2 3 3 4
K1, K2 Flushing port M33x2 M33x2 M42x2 M42x2
R(L) Oil fill or bleed port M33x2 M33x2 M42x2 M42x2
M1, M2 Gauging port control pressure M14x1,5 M14x1,5 M18x1,5 M18x1,5
RE 92 088/08.04 | Electro-hydraulic Control system DFE1 Industrial Hydraulics | Bosch Rexroth AG 11/12

Safety information
– Pump A4VSO was designed for operation in open loop circuits.
– Systems design, installation and commissioning require trained technicians or tradesmen.
– All hydraulic ports can only be used for the fastening of hydraulic service lines.
–Tightening torques:
The tightening torques mentioned in this data sheet are maximum values and must not be exceeded (max. values for thread).
Manufacturers information concerning the maximum permitted tightening torques of the various fittings are to be observed!
For DIN 13 mounting bolts, we recommend that tightening torques be checked on a case by case basis in accordance with
VDI 2230, published 2003.
– During and shortly after operation of a pump the housing and especially a solenoid can be extremely hot, avoid being
burned!
12/12 Bosch Rexroth AG | Industrial Hydraulics Electro-hydraulic Control system DFE1 | RE 92 088/08.04

Bosch Rexroth AG © This document, as well as the data, specifications and other informations set
Mobile Hydraulics forth in it, are the exclusive property of Bosch Rexroth AG. Without their consent
Product Segment Axial Piston Units it may not be reproduced or given to third parties.
Plant Horb The data specified above only serve to describe the product. No statements
An den Kelterwiesen 14 concerning a certain condition or suitability for a certain application can be
72160 Horb am Neckar, Germany derived from our information. The given information does not release the user
Phone +49 (0) 74 51 - 92 0 from the obligation of own judgement and verification. It must be remembered
Telefax +49 (0) 74 51 - 82 21 that our products are subject to a natural process of wear and aging.
info.brm-ak@boschrexroth.de Subject to change.
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