Possibilities of converting a variable displacement pump ...

RE 30637032015 Technical information Bosch Rexroth AG

Possibilities of converting a variable displacement pump A4VSO into a DFE control

Contents

General 11 Pumps suitable for conversion 22 Conversion into DFE control system 421 Demounting of the existing controller 422 Components required for conversion 5 23 Mounting orientation of the sandwich plate 624 Mounting of the swivel angle sensor (1) and the pilot

valve (4) 725 Mounting of the threaded pin (3) 726 Selection of the pressure transducer (5) 827 Adjustment of the Qmin limit stop 928 Calibration and commissioning of the control

system 103 Supplementary documentations 11

RE 30637thinspEdition 032015Technical information

General

The present technical information describes the possibilities of converting A4VSO variable displacement pumps of series 10 11 30 into energy-efficient variable displacement pumps with DFE control and thus to utilize their advantages

Generally required for the conversion is the use of a VT-DFPx pilot valve of a VT-SWA-LIN swivel angle sensor of a pressure transducer as well as of a sandwich plate for mounting the high-response valve

212 Technical information | Conversion of A4VSO into DFE

Bosch Rexroth AG RE 30637032015 Technical information

1 Pumps suitable for conversion

A4VSO pumps of series 10 in sizes 40 and 71 as well as A4VSO pumps of series 30 in sizes 125 to 355 are generally suitable for a conversion An axial piston unit can be identified on the nameplate as shown by the following example

7201

richtungDreh-

SN

Made in Germany

12345678

xxxxxxxxxxxx

MNR FD

Rexroth A4VSO250LR230R-PPB13N00

08W06

1

6

23

491011

12

578

13

14

1 Manufacturer 2 Date of production3 Internal factory designation 4 Direction of rotation (viewed to the drive shaft - shown here

clockwise)5 Power adjustment (optional) 6 Bar code7 Speed 8 Flow adjustment (optional)9 Pressure controller adjustment (optional) 10 Displacement11 Serial number 12 Material number of the axial piston unit13 Type code 14 Customer number

Further restrictions and details can be derived from the type code

01 02 03 04 05 06 07 08 09 10 11 12 13 14A4VS O 250 LR2 30 R ndash P P B 13 N00

Pumps with the following order codes in the type code are suitable for conversionAxial piston unit

02 Swashplate design variable displacement 4VS

Operating mode

04 Pump open circuit O

Size 40 71 125 180 250 355

05 Displacement Vg max [cm3] 40 71 125 180 250 355

Series

07 - - - - 1011

- - 30

Conversion of A4VSO into DFE | Technical information 312

Technical information RE 30637032015 Bosch Rexroth AG

Pumps with the following control and adjustment elements are suitable for conversion

Control and adjustment element06 Electrohydraulic control system DFE1 DFE1

Pressure controller DRPressure controller remote controlled DRG

Pressure controller for parallel operation DPPressure and flow controller DFRFlow controller FRPower controller with hyperbolic curve (exception LrxN) LR2 LR3

At position 14 of the type code further details such as an SO variant can be specified In conjunction with SO variants further measures may be required for the conversion In these cases please consult us The following SO variants do not differ from standard systems with regard to the conversion because here only the controller which is no longer required after the conversion is modified but not the base pump

14 DRG+ DBETR SO91DRG + standby unloaded when de-energized SO580DP + SO680 SO680LRx-SO134 SO134LRxG-SO762 SO762LRxS-S1167 S1167LRxG-S1475 S1475

Pumps with the following control and adjustment elements are NOT suitable for conversionControl and adjustment element

06 Power controller with hyperbolic curve LRx(x)NManual control MAElectric motor control EM

Hydraulic control related to flow HMHydraulic control with servoproportional valve HSElectronic control EOHydraulic control related to pressure HDElectro-proportional control EPSpeed control secondary-controlled DS1

Features 8 to 13 are irrelevant for the suitability for conversion

The conversion must generally be carried out by Bosch Rexroth Service



2 Conversion into DFE control system

21 Demounting of the existing controllerRelevant for the disassembly are the swivel angle feedback (1 and 3) as well as the controller with sandwich plate (2) To see which components have to be removed from which pump variant please refer to the table below

Demounting required

Ordering code 06

Swivel angle feedback (SWA)(1)

Controller sandwich plate (2)

Swivel angle feedback (power) (3)

DFE Yes Yes No

DR No Yes NoDRG-SO91 No Yes No

DRG-SO580 No Yes NoDP Yes Yes No

DP-SO680 No Yes NoDRF No Yes NoFR No Yes No

LR2 LR3 No Yes YesLRxH Yes Yes Yes

LRx-SO134 No Yes YesLRxG-SO762 Yes Yes YesLRxS-S1167 No Yes YesLRxG-S1475 No Yes Yes

) If no swivel angle feedback is installed the cavity is plugged with a plug screw

1

2

3

Controller item 2 must always be removed

Fig 1 Pump after removal of all relevant parts



22 Components required for conversion

221 Series 1011 (sizes 40 71)Mounting

Ordering code 06

Swivel angle sensor VT-SWA-LIN (1)

Sandwich plate (2) Threaded pin (3) Pilot valve (4) Pressure transducer (5)

DFE

Depending on size

NG 40R901014812VT-SWA-LIN-1XG10-1-K44

NG 71R901014815VT-SWA-LIN-1XG10-2-K44

(mounting material in-cluded)

Not required Not required

Selection according to data sheet 29016

VT-DFPE-2XVT-DFPC-2XVT-DFPn-2X

In addition 4 valve mounting screws for all types

R913000058ISO4762-M6x40-109-flZn-240h-L

Selection accord-ing to data sheet 30272

HM20-2X 420 mA

HM20-2X (01hellip10 V)


DR

Mounting requiredR910922350 SANDWICH PLATEA4A10V

(mounting material included)

Mounting requiredR910118818 THREADED PIN DIN913-M5x8 In addition Loctite 242

DRG

DP

DRF

FR

LR2 LR3Mounting requiredR910100951 THREADED PIN DIN913-M6x8-109In addition Loctite 242

LRxH

222 Series 30 (sizes 125 - 355)

MountingOrdering code

06Swivel angle sensor

VT-SWA-LIN (1)Sandwich plate (2) Threaded pin (3) Pilot valve (4) Pressure

transducer (5)

DFE

Depending on size

NG 125 - 180R901014812VT-SWA-LIN-1XG10-1-K44

NG 250 - 355R901000272VT-SWA-LIN-1XG10-3-K44 (mounting material included)

Not required

Already available




R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR

Mounting requiredR902443354SANDWICH PLATEA4VS 125-355 FE130 V


DRG

DP

DRF

FR


LRxH



Fig 4 Clockwise rotating pump of series 30 viewed from the rear with sandwich plate mounted

Fig 5 Counter-clockwise rotating pump of series 30 viewed from the rear with sandwich plate mounted

232 Mounting orientation of sandwich plate R902443354 (2) with series 30

Strictly observe the correct orientation of all individual parts of the sandwich plate



23 Mounting orientation of the sandwich plate




R(L)

15

15

0

LR

Fig 6 Top view

24 Mounting of the swivel angle sensor (1) and the pilot valve (4)

1

4

The swivel angle sensor (1) VT-SWA-LIN must be installed and calibrated according to data sheet 30263The pilot valve (4) for control system SY(H)DFE must be installed according to data sheet 29016

25 Mounting of the threaded pin (3)

Position of threaded pin R910100951

The pilot oil bores of the actuating piston must in any case be plugged To see for which pump variant a threaded pin must be installed please refer to the overview ldquoComponents required for the conversionrdquoFor plugging screw in threaded pin R91010095 according to DIN 913 M6x8-109 or threaded pin R910118818 according to DIN 913 M5x8 using Loctite 242

On the counter-clockwise rotating unit the construction of the actuating system is mirrored




26 Selection of the pressure transducer (5)

The pressure rating should be adapted to the maximum operating pressure of the application The permitted maximum operating pressure of the control system is 350 barIn terms of signals the sensors have to be distinguished as followsbull Sensors with current interfacebull Sensors with voltage interface

Pressure transducer Material number Data sheetHM20-2X measuring range 400 bar (420 mA) R901342033 30272HM20-2X measuring range 400 bar (0110 V) R901342034 30272HM20-2X measuring range 315 bar (055 V) R901342038 30272

It is possible to connect the pressure transducer of type HM 20-2X315-F-C13-05 R901342038 (up to 315 bar) directly by means of an M12 connector to valves with integrated electronics For this purpose the pressure transducer is provided with a 05 m cable For this variant feature 9 must be selected in the valve type code ldquoFrdquo (voltage input 055 V) Since both cabling and voltage supply are fixed in this case these points do not require particular attention

If required other pressure ratings can be used (with the correct selection of the relevant electrical interface)

Further notes on the selection place of installation and mounting orientation of the pressure transducer can be found in the operating instructions RE 30011-B RE 30012-B RE 30014-B und RE 30027-B depending on the variant of the selected high-response valve



27 Adjustment of the Qmin limit stop

In contrast to the SYHDFEx variant as delivered ex works a converted unit can in most of the cases be adjusted only within the range of 0 to 100 swivel angle If this is sufficient for the planned application parameter R219 must be set to the value 0 if VT-DFPN pilot valves are installedShould it be possible to adjust the swivel angle within the range of -100 to 100 (pressure reduction etc) the Qmin limit stop must be replaced In this case the parameter needs not to be adapted As substitute for the Qmin limit stop the following plug screws must be installed bull NG40 R909156650 PLUG SCREW ZN10001-M12X15-F-ST bull NG71 R909153930 PLUG SCREW ZN10001-M14X15-F-ST bull NG125 R909156864 PLUG SCREW ZN10001-M16X15-F-ST bull NG250 R909157040 PLUG SCREW ZN10001-M20X15-F-ST

This conversion may only be carried out on sizes 40 71 125 and 250 Sizes 180 and 355 are only released for negative swivel angles with the original DFE control system converted pumps of these two sizes must not swivel to the negative range

Fig 7 View of the clockwise rotating pump with Qmin limit stop at 0 displacement

Fig 8 View of the clockwise rotating pump without Qmin limit stop with plug screw

In the case of a counter-clockwise rotating unit the Qmin limit stop can be found on the opposite side From year of construction 2014 (see nameplate item 2) the Qmin limit stop can no longer be removed from outside In this case the spring-loaded cover of the adjustment element must be removed and the limit stop turned out inwards



28 Calibration and commissioning of the control system

Commissioning of the converted control system is described in the operating instructions 30012-B 30014-B and 30027-BSettings must be made on the control system to achieve proper functioning and best possible control quality This work is also described in the operating instructions mentioned before They comprise bull Zero point and gain calibration of the swivel angle sensor bull Calibration of the pressure transducer bull Optimization of the pressure controller

Depending on the variant of the high-response valve additional adjustment options may be available such as power limitation and variable-speed operationIn the case of digital valves VT-DFPC and VT-DFPn the settings may also be made digitally

NoteThe technical data given in the data sheet of the variable displacement axial piston pump A4VSO RE 92050 are also valid after the conversion This applies in particular to the speed limits



Title Document no

Type of document

Pressure and flow control system type SYHDFEE-1X SYHDFEC-1X 30035 Data sheetVariable-speed pressure and flow control system Sytronix DFEn 5000 type SYHDFEN-1X 62242 Data sheetPressure and flow control system type SYDFEE2X 3X SYHDFEE1X 30012-B Operating instructionsClosed-loop control system type SYHDFEC-1X 30027-B Operating instructionsVariable-speed pressure and flow control system Sytronix DFEn 5000 30014-B Operating instructionsCANopen interface for variable-speed pressure and flow control system Sytronix DFEn 5000 30014-02-Z Supplementary informa-

tionUniversal through-drive A10VSO A4VSO A15VSO and A11V(L)O 95581 Data sheetAxial piston variable pump A4VSO 92050 Data sheetAxial piston variable pump A4VSO for HFC fluids 92053 Data sheet33 proportional directional valves direct operated with electrical position feedback as pilot valves for control systems SY(H)DFE

29016 Data sheet

Swivel angle sensor VT-SWA-LIN 30263 Data sheetPressure transducer for hydraulic applications type HM20-2X 30272 Data sheetPressure transducer for hydraulic applications type HM20-2X 30272-MON Installation instructionsTest unit VT-PDFE-1X for closed-loop control systems SYDFE 29689-B Operating instructions

3 Supplementary documentations

Bosch Rexroth AG Zum Eisengieszliger 197816 Lohr am Main Germany Telephone +49 (0) 93 52thinspthinsp18-0 documentationboschrexrothde wwwboschrexrothde

copy This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth It may not be reproduced or given to third parties without its consentThe data specified only serve to describe the product No statements concerning a certain condition or suitability for a certain application can be derived from our information The information given does not release the user from the obligation of own assessments and verification It must be remembered that our products are subject to a natural process of wear and aging



Pumps suitable for conversion

Conversion into DFE control system

Supplementary documentations



1 Pumps suitable for conversion

A4VSO pumps of series 10 in sizes 40 and 71 as well as A4VSO pumps of series 30 in sizes 125 to 355 are generally suitable for a conversion An axial piston unit can be identified on the nameplate as shown by the following example

7201

richtungDreh-

SN

Made in Germany

12345678

xxxxxxxxxxxx

MNR FD

Rexroth A4VSO250LR230R-PPB13N00

08W06

1

6

23

491011

12

578

13

14

1 Manufacturer 2 Date of production3 Internal factory designation 4 Direction of rotation (viewed to the drive shaft - shown here

clockwise)5 Power adjustment (optional) 6 Bar code7 Speed 8 Flow adjustment (optional)9 Pressure controller adjustment (optional) 10 Displacement11 Serial number 12 Material number of the axial piston unit13 Type code 14 Customer number

Further restrictions and details can be derived from the type code

01 02 03 04 05 06 07 08 09 10 11 12 13 14A4VS O 250 LR2 30 R ndash P P B 13 N00

Pumps with the following order codes in the type code are suitable for conversionAxial piston unit

02 Swashplate design variable displacement 4VS

Operating mode

04 Pump open circuit O

Size 40 71 125 180 250 355

05 Displacement Vg max [cm3] 40 71 125 180 250 355

Series

07 - - - - 1011

- - 30


















Demounting required

Ordering code 06




DFE Yes Yes No







1

2

3







Ordering code 06



DFE

Depending on size

NG 40R901014812VT-SWA-LIN-1XG10-1-K44

NG 71R901014815VT-SWA-LIN-1XG10-2-K44






R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR




DRG

DP

DRF

FR


LRxH

222 Series 30 (sizes 125 - 355)




transducer (5)

DFE

Depending on size

NG 125 - 180R901014812VT-SWA-LIN-1XG10-1-K44


Not required

Already available




R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR



DRG

DP

DRF

FR


LRxH













R(L)

15

15

0

LR

Fig 6 Top view


1

4































Title Document no

Type of document



29016 Data sheet



























Demounting required

Ordering code 06




DFE Yes Yes No







1

2

3







Ordering code 06



DFE

Depending on size

NG 40R901014812VT-SWA-LIN-1XG10-1-K44

NG 71R901014815VT-SWA-LIN-1XG10-2-K44






R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR




DRG

DP

DRF

FR


LRxH

222 Series 30 (sizes 125 - 355)




transducer (5)

DFE

Depending on size

NG 125 - 180R901014812VT-SWA-LIN-1XG10-1-K44


Not required

Already available




R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR



DRG

DP

DRF

FR


LRxH













R(L)

15

15

0

LR

Fig 6 Top view


1

4































Title Document no

Type of document



29016 Data sheet














Ordering code 06



DFE

Depending on size

NG 40R901014812VT-SWA-LIN-1XG10-1-K44

NG 71R901014815VT-SWA-LIN-1XG10-2-K44






R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR




DRG

DP

DRF

FR


LRxH

222 Series 30 (sizes 125 - 355)




transducer (5)

DFE

Depending on size

NG 125 - 180R901014812VT-SWA-LIN-1XG10-1-K44


Not required

Already available




R913000058ISO4762-M6x40-109-flZn-240h-L


HM20-2X 420 mA



DR



DRG

DP

DRF

FR


LRxH













R(L)

15

15

0

LR

Fig 6 Top view


1

4































Title Document no

Type of document



29016 Data sheet






















R(L)

15

15

0

LR

Fig 6 Top view


1

4































Title Document no

Type of document



29016 Data sheet


































Title Document no

Type of document



29016 Data sheet










Possibilities of converting a variable displacement pump ...

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