Proportional Directional Control Valves

PRM6-10

HA 5115 8/2005

Size 10 (D 05) ... 320 bar (4600 PSI) ...80 L/min (21 GPM )

q q q

Compact design with integrated electronics High reliability Simple replacement of the exciting coils including electronics without opening the hydraulic circuits Continuous flow control in both directions Installation dimensions to DIN 24 340 / ISO 4401 / CETOP RP121-H

q q

Functional Description
The proportional directional valve consists of a cast-iron housing, a special control spool, two centering springs with supporting washers and one or two proportional solenoids. A control box, which comprises one or two electronic control cards, depending on the number of the controlled solenoids, can be mounted onto either solenoid. With the model with two solenoids, the solenoid mounted apposite the control box is connected with the box by means of a EN connector, a two-cored cable and a bushing. The connection of the control box with the supply source and with the control signal is realized by means of a 4-pin connector, type M12 x 1. The solenoid coils, including the o control box, can be turned in the range of 90 . The electric control unit supplies the solenoid with current, which varies with the control signal. The solenoid shifts the control spool to the required position, proportional to the control current. The electronic control unit provides the following adjustment possibilities: Offset, Gain, rise and drop-out time of the ramp generator, frequency (2 frequencies) and amplitude of the dither signal generator. The correct function of the control unit is signaled by LED-diodes. Stabilized voltage +10V (+5V for 12V voltage) is also available for the user. By the use of this voltage, a voltage control signal can be made by means of a potentiometer 1 kW. The electronic control card enables voltage or current control to be used, according to the positions of the switches SW1 to SW3 (see table on page 6). The basic surface treatment of the valve housing is phosphate coated, the operating solenoids are zinc coated.

HA 5115

Ordering Code PRM6-10

Proportional Directional Control Valve without designation

Seals

V
Nominal size

NBR FPM (Viton)

10 (D 05)

2Z51

2Z11
Electronics without designation without electronics

2Y51

EK

2Y11

connection by connector M12 x 1 (4-pin connector) (supplied with counterpart)

3Z11

3Z11B
qA qB qA qB = 1* 2 1* 2

3Z12
Nominal supply voltage

3Z12B

12 24

12 V DC 24 V DC

3Y11

3Y11B
qA qB qA qB = = 1* 2 1* 2

3Y12
Nominal flow rate at Dp = 10 bar (145 PSI)

3Y12B

30 60

30 L/min (7.93 GPM) 60 L/min (15.85 GPM)

* Model for cylinders with asymmetric piston rod, piston area ratio 1:2

HA 5115

Technical Data
Valve size Maximum operating pressure at ports P, A, B Maximum operating pressure at port T Hydraulic fluid Fluid temperature range NBR / Viton Ambient temperature, max. Viscosity range Maximum degree of fluid contamination Nominal flow rate Qn at Dp = 145 PSI (10 bar) n = 32 mm2s-1(n = 156 SUS ) Hysteresis Weight PRM2-102 PRM2-103 Mounting position Enclosure type to EN 60529 L/min (GPM) % kg (lbs)
2

mm (US) bar (PSI) bar (PSI)

10 (D 05) 320 (4600) 210 (3046) Hydraulic oils of power classes (HL, HLP) to DIN 51524

C (F) C (F) mm /s (SUS)

-30 ... +80 (-22 ... +176) / -20 ... +80 (-4 ... +176) +50 (+122) 20 ... 400 (98 ... 1840 ) Class 21/18/15 to ISO 4406 (1999). 30 (7.93) / 60 (15.85) 6 4.3 (9.48) 5.8 (12.78 ) any, preferably horizontal IP65

Technical Data of the Proportional Solenoid

Nominal supply voltage Limit current Mean resistance value at 20 C (68 F)
o

V A W

12 DC 10 % 1.9 4.7

24 DC 10 % 1.1 13.9

Technical Data of the Electronics

Nominal supply voltage Ucc Supply voltage range Stabilized voltage for control Control signal Maximum output current Ramp adjustment range Dither frequency Dither amplitude A s Hz % Measured at n = 32 mm2/s (166 SUS) Nominal flow 60 L/min (15.85 GPM) V V V 12 DC 11.2 ... 14.7 DC 5 DC (R > 1 kW) 24 DC 20 ... 30 DC 10 DC (R 1 kW)

see table of switches configuration (page 6) 2.4 for R < 4W 0.05 ... 3 90 / 60 0 ... 30 1.5 for R < 10W

Limit Power

Nominal flow 30 L/min (7.93 GPM)

Input pressure po [PSI] 0 725 1450 2176 2901 3626 4351 5076 70 18.5

0 100

Input pressure po [PSI] 1000 2000 3000 4000 5000

P A / B T or P B / A T

Flow Q [L/min]

60 P A / B T or P B / A T 50 40 30 20 10 0 50 4 3 2 1 100 150 200 250 300 350 Input pressure po [bar]

15.9

26.4

Flow Q [GPM]

Flow Q [L/min]

13.2 10.6 7.9 5.3 2.6 0

80 60 4 40 20 3 2 1 0 50 100 150 200 250 300 350 Input pressure po [bar]

15.9 10.6 5.3 0

Solenoid curren t:(24 V DC) 1 = 40% 2 = 60% 3 = 80% 4 = 100% 3

Flow Q [GPM]

21.1

HA 5115

Flow Characteristic with Integrated Electronics

Measured at Dp = 10 bar (145 PSI), n = 32 mm2/s (156 SUS)

100 80 60 40
Flow Q [%]

20 0 -20 -40 -60

-80 -100 -100 -80

-60

-40

-20

20

40

60

80

100

Control signal ux [%]

Flow Characteristic without Integrated Electronics

2 Measured at Dp = 10 bar (145 PSI), n = 32 mm /s (156 SUS),

100 75 50
Flow Q [%]

25 0 -25 -50 -75 -100 -1100 -1000 -800 -600 -400 -200 0 200 400 600 800 1000 1100 (400) (800) (1200) (1600) (1900)
Values in parenthesis are valid for the supply voltage 12 V.

(-1900) (-1600) (-1200) (-800) (-400) 0

Exciting current Ic [mA]

The coil current which initializes the flow through the proportional directional valve can differ due to the production tolerances about in a range of 6% of the limit current.

Transient Characteristic
2 Measured at Dp = 10 bar (145 PSI), n = 32 mm /s (156 SUS); Q = 80 %Qn

Spool position s [%]

Steady spool position ss [%] 100 75 95% ss 5% 50 25

t2 [ms] 160 135 85 50

t4 [ms] 145 130 105 70

t2

t4 Time t [ms]

the control signal course of the integrated electronics 4

The values in table have only an informative character. The times of the transient characteristics at pressure or flow control will be in a particular hydraulic circuit always longer.

HA 5115

Frequency Reponse
------ signal 90% signal 25%

1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 0,1 1

Frequency [Hz]

160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 10 12

Amplitude ratio [dB]

Component Arrangement on the Electronic Card

LED

DOWN

OFFSET

DITHER

GAIN

UP

SW4

SW1 SW2 SW3 SW4 -

control signal choice control signal choice control signal choice dither frequency

SW2

SW3

FUSE SW1 connector

MASTER for solenoid a or b

(1) (2)

(4) (3)

3
4 2 3 1

(4) (2) (3) (1)

SLAVE for solenoid b or a

Description basic subplatte

Electronic Card MASTER

PIN 1 2

Description +24 V (Ucc) (+12 V) control 0V +10 V (+5 V)

1 3 2 4

3
solenoid a (b)

solenoid b (a)

Electronic Card SLAVE

Phase lag [degrees] 5

HA 5115

Table of the Switch Configuration for the Control Signal Choices

PRM6-102 0 ... 5 V 0 ... 10 V (0 ... 5 V)* 0 ... 20 mA 4 ... 20 mA PRM6-103 Ucc/2 10 V ( 5 V)* 10 V ( 5 V)*

SW1

SW2 MASTER M SW3

SW4 90 Hz

60 Hz

SW1

SW2 SLAVE S SW3

SW4

90 Hz

60 Hz

Designation of the basic manufacture setting. The ramp functions are adjusted on their minimum values, the dither is set to the optimal value with respect to hysteresis. Offset and Gain are adjusted according to the characteristic on page 3 and 4. The manufacturer does not recommend these adjusted values to be changed. * Input signal level for the 12 V electronic unit.

Block Diagram
10 V DC (5 V DC) STABILIZED VOLTAGE FOR EXTERNAL USE GAIN RAMPS OFFSET U/I

CONROL

DITHER

OUTPUT TO THE SOLENOID COIL

CONTROL CONNECTION MASTER AND SLAVE

HA 5115

Valve PRM6-102 (with One Solenoid)

1 Factory setting 1.1 Control with external voltage source 0 ... 10 V (0 ... 5 V) or with external potentiometer R >1 kW Notice:
The control signal must have the same ground potential as the supply source.

Master card for solenoid a (b)

LED

DOWN

SW4

SW2 SW3

FUSE SW1

connector factory connected

OFFSET

DITHER

GAIN

UP

solenoid a (b)

(4) (2) (3) (1)

4 2 3 1 10V DC (5V DC)

not used control 0 ... 10 V (0 ...5V) 0V +24 V

R > 1 kW

3 0V 1 +24 V(+12 V)

(1) (2)

(4) (3)

Wire colours (connection connector - electronics):

(1) - brown (2) - white (3) - blue (4) - black MASTER for solenoid a (b)

Factory set values:

Control signal: 0 - 10 V (0 - 5V) Dither: frequency 90Hz amplitude - optimum Ramps: 0.05 s Offset, Gain: according to the characteristics on page 3, 4 7

HA 5115

Valve PRM6-102 (with One Solenoid)

2 Other control possibilities 2.1 Control with external source 0 ... 5 V Notice:
The control signal must have the same ground potential as the supply source.

Master card for solenoid a (b)

LED

DOWN

SW4

SW2 SW3

FUSE SW1

connector factory connected

OFFSET

DITHER

GAIN

UP

solenoid a (b)

(4) (2) (3) (1)

4 2 3 1

not used control 0 ... 5 V 0V +24 V

(1) (2)

(4) (3)

MASTER for solenoid a (b)

For the factory setting modification for this case of application, the following steps are required: 1. Unscrew the electronics cover 2. Carefully remove the Master card 3. Flip the switch SW3 in position shown in the picture 4. Put in the Master card and fix the electronics cover 5. Connect the voltage +24 V from an external supply source to terminals 1 and 3 of the connector 6. Connect the control voltage 0 5 V from an external source to terminals 2 and 3 of the connector

HA 5115

Valve PRM6-102 (with One Solenoid)

2.2 Control with external source 0 ... 20 mA Notice:
The control signal must have the same ground potential as the supply source.

Master card for solenoid a (b)

LED

DOWN

SW4

SW2 SW3

FUSE SW1

connector factory connected

OFFSET

DITHER

GAIN

UP

solenoid a (b)

(4) (2) (3) (1)

4 2 3 1

not used control 0 ... 20mA 0V +24 V (+12 V)

(1) (2)

(4) (3)

MASTER for solenoid a (b)

For the factory setting modification for this case of application, the following steps are required: 1. Unscrew the electronics cover 2. Carefully remove the Master card 3. Flip the switch SW1 and SW3 in position shown in the picture 4. Put in the Master card and fix the electronics cover 5. Connect the voltage +24 V (+12 V) from an external supply source to terminals 1 and 3 of the connector 6. Bring the control current 0 20 mA from an external source to terminals 2 and 3 of the connector

HA 5115

Valve PRM6-102 (with One Solenoid)

2.3 Control with external source 4 ... 20 mA Notice:
The control signal must have the same ground potential as the supply source.

Master card for solenoid a (b)

LED

DOWN

SW4

SW2 SW3

FUSE SW1

connector factory connected

OFFSET

DITHER

GAIN

UP

solenoid a (b)

(4) (2) (3) (1)

4 2 3 1

not used control 4 ... 20mA 0V +24 V (+12 V)

(1) (2)

(4) (3)

MASTER for solenoid a (b)

For the factory setting modification for this case of application, the following steps are required: 1. Unscrew the electronics cover 2. Carefully remove the Master card 3. Flip the switch SW1, SW2 and SW3 in position shown in the picture 4. Put in the Master card and fix the electronics cover 5. Connect the voltage +24 V (+12 V) from an external supply source to terminals 1 and 3 of the connector 6. Bring the control current 4 20 mA from an external source to terminals 2 and 3 of the connector

10

HA 5115

Valve PRM6-103 (with Two Solenoids)

3 Factory setting 3.1 Control with external source 0 10 V (0 5 V) Notice:
The control signal must have the same ground potential as the supply source.

Master card for solenoid a (b)

LED DOWN

UP

OFFSET

DITHER

SW4

SW2 SW3

FUSE SW1 solenoid b (a) connector solenoid a (b)

GAIN

(4) (2) (3) (1)

factory connected

4 2 3 1

not used control 10 V(5 V) 0V +24 V (+12 V)

Slave card for solenoid b (a)

LED OFFSET DOWN DITHER GAIN UP SW2 SW3

SW4

FUSE SW1

Factory set values:

connector

Control signal: 0 10 V (0 5V) Dither: frequency 90 Hz amplitude - optimum Ramps: 0.05 s Offset, Gain: according to the characteristics on page 3, 4 4 1 (1) (4) (2) (3)

MASTER for solenoid a (b) SLAVE for solenoid b (a)

11

HA 5115

Valve PRM6-103 (with Two Solenoids)

3.2 Other control possibilities Control Ucc/2 10 V(Ucc/2 5V) external potentiometer R > 1 kW

DITHER

solenoid a (b)

LED

Master card for

DOWN

UP

SW4

SW2 SW3

FUSE SW1 connector solenoid b (a) solenoid a (b)

OFFSET

GAIN

factory connected (4) (2) (3) (1) R > 1 kW

3 0V 1 +24 V (+12 V)

SW4

SW2 SW3

FUSE SW1 connector

OFFSET

DITHER

DOWN

Slave card for solenoid b (a)

LED

GAIN

UP

MASTER for solenoid a (b) SLAVE for solenoid b (a) 4 1

(1) (2)

(4) (3)

For the factory setting modification for this case of application, the following steps are required: 1. Unscrew the electronics cover 2. Carefully remove the Master card 3. Flip the switch SW1 in position shown in the picture 4. Put in the Master card and fix the electronics cover 5. Connect the voltage +24 V (+12 V) from an external supply source to terminals 1 and 3 of the connector 12

HA 5115

Ramp Adjustment (Up, Down)

Notice: The factory setting of the ramp functions is to the minimum values.
100 Up Down

Q [%]

0.05 s* 3.00 s

0.05 s* 3.00 s

t [s]

*The value has only an informative character with respect to the particular type of the proportional directional valve (see page 4)

270

270

Ramp adjustment for Master solenoid

UP DOWN

Up

Down

Up

Down

Ramp adjustment for Slave solenoid

Dither Adjustment
Notice: The dither is adjusted with regard to the minimum hysteresis. Amplitude - potentiometer (dither) (0 - 30 %)
Iout [%]

Frequency - switch SW4

0%

90 Hz

60 Hz

270 Amplitude adjustment for Master solenoid t [s] Iout [%] 15 %

SW4 DITHER

t [s] Iout [%] 30 % Amplitude adjustment for Slave solenoid

t [s] 13

HA 5115

Adjustment of Offset, Gain Parameters

Notice: The factory setting of the Offset and Gain parameters is specific for the solenoids used. The manufacturer does not recommend this setting to be changed.

Q [%] 100

Offset

Q [%] 100

Gain

uxx

100 ux [%]

ux

100 ux [%]

+
Offset 270

Gain

270

Adjustment of Offset
OFFSET GAIN

Gain for Master solenoid

Adjustment of Offset

Gain for Slave solenoid

Nominal supply voltage of electronics [V] 12 24

Area insensible to control signal uxx [%] 1 ... 3 0.5 ... 2

14

HA 5115

Valve Dimensions
PRM2-102..../..-...

Dimensions in millimetres ( in inches )

Functional symbols 2Z51, 2Y51

HEX 32

Functional symbols 2Z11, 2Y11

1 2 3 4 5 6 7

Solenoid a Solenoid b Name plate Square ring 12.42 x 1.68 (5 pcs.) supplied in delivery packet 4 through mounting holes Solenoid fixing nut [Nut torque 6 Nm (4.43 Ibf.ft )] Manual override

Required surface finish of interface. 15

HA 5115

Valve Dimensions

Dimensions in millimetres ( in inches )

PRM6-103..../..-...

Functional symbols 3Z11, 3Z12, 3Y11, 3Y12

1 4

HEX 36

1 2 3 4 5 6 7

Solenoid a Solenoid b Name plate Square ring 12.42 x 1.68 (5 pcs.) supplied in delivery packet 4 through mounting holes Solenoid fixing nut [Nut torque 6 Nm (4.43 Ibf.ft )] Manual override

Required surface finish of interface.

16

HA 5115

Valve Dimensions
PRM6-102..../..-..EK..

Dimensions in millimetres ( in inches ) Functional symbols 2Z51, 2Y51

3 8

HEX 36

PRM6-102...B/..-..EK..

Functional symbols 2Z11, 2Y11

2
1 2 3 4 5 6 7 8 Solenoid a Solenoid b Name plate Square ring 12.42 x 1.68 (5 pcs.) supplied in delivery packet 4 through mounting holes Solenoid fixing nut [Nut torque 6 Nm (4.43 Ibf.ft )] Manual override 4- pin connector M12 x 1 for external supply voltage

Required surface finish of interface. 17

HA 5115

Valve Dimensions
PRM6-103..../..-..EK..

Dimensions in millimetres ( in inches ) Functional symbols 3Z11, 3Z12, 3Y11, 3Y12

HEX 36

PRM6-103...B/..-..EK..

Functional symbols 3Z11B, 3Z12B, 3Y11B, 3Y12B

1 2 3 4 5 6 7 8 18

Solenoid a Solenoid b Name plate Square ring 12.42 x 1.68 (5 pcs.) supplied in delivery packet 4 through mounting holes Solenoid fixing nut [Nut torque 6 Nm (4.43 Ibf.ft )] Manual override 4- pin connector M12 x 1 for external supply voltage

Required surface finish of interface.

HA 5115

Spare Parts
1 2 3 4 5 6 Solenoid coil Nut + seal ring Connector plug EN 175301-803 Seal kit Bolt kit Connector

3 1

2 6

4
1. Solenoid coil Nominal supply voltage [V] 12 24 2. Solenoid retaining nut + seal ring Model of the nut Standard nut 3. Connector plug to EN 175301-803 Connector plug A gray Connector plug B black Seal ring 30 x 2 Ordering number 489-9900 Ordering number 936-4614 936-4629

Type designation

Type

Maximum input voltage

Ordering number K5 4. Seal kit Type Standard - NBR 70 Viton 5. Bolt kit Dimensions, number M6 x 40 DIN 912-10.9 (4 pcs.) 6. Connector M12 x 1 ( 4-pin connector) Tightening torque 14 Nm (10.33 Ibf.ft) Ordering number 485-9964 Ordering number 358358904012 Dimensions, number 12.42 x 1.68 (5 pcs.) 12.42 x 1.68 (5 pcs.) 23.81 x 2.62 (2 pcs.) 23.81 x 2.62 (2 pcs.) Ordering number 489-9902 489-9903 without rectifier - M16x1.5 bushing bore 4-6 mm ( 0.16-0.24 in) 230 V DC 936-9906 936-9905

19