Bosch Rexroth RA 10 Series User manual

Instruction manual
RE95230-B/2021-12-01, replaces: 08.2015, EN
Analog amplifier
RA

© BoschRexrothAG2021. All rights reserved,
also regarding any disposal, exploitation,
reproduction, editing, distribution, as well
as in the event of applications for industrial
property rights.
The data specified within only serves
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 judgment and verification. It must be
remembered that our products are subject to
anatural process of wear and aging.
The cover shows an example application.
The product delivered may differ from the
image on the cover.
The original instruction manual was created
in German.

RE95230-B/2021-12-01, BoschRexrothAG
Contents | Analog amplifier RA 3/48
Contents
1 About this documentation ������������������������������������������������������������������������ 5
1.1 Validity of the documentation ...................................................................... 5
1.2 Required and supplementary documentation............................................... 5
1.3 Representation of information...................................................................... 5
1.3.1 Safety instructions ....................................................................................... 5
1.3.2 Symbols ....................................................................................................... 6
1.3.3 Designations ................................................................................................ 7
1.3.4 Abbreviations ............................................................................................... 7
2 Safety instructions ����������������������������������������������������������������������������������� 8
2.1 About this chapter........................................................................................ 8
2.2 Intended use ................................................................................................ 8
2.3 Improper use................................................................................................ 8
2.4 Personnel qualifications ............................................................................... 9
2.5 General safety instructions .......................................................................... 9
2.6 Product-specific safety instructions ........................................................... 11
2.7 Personal protective equipment...................................................................11
3 General instructions on property damage and product damage�������������� 12
4 Scope of delivery������������������������������������������������������������������������������������ 13
5 About this product ��������������������������������������������������������������������������������� 14
5.1 Product description ................................................................................... 14
5.2 Features ..................................................................................................... 14
5.3 Operating modes........................................................................................ 15
5.4 Assignment and function of the LEDs and setting potentiometer ............... 16
5.5 Identification of RA .................................................................................... 17
6 Transport and storage ���������������������������������������������������������������������������� 18
6.1 Transporting and storing the analog amplifier ............................................ 18
7 Installation��������������������������������������������������������������������������������������������� 19
7.1 Unpacking .................................................................................................. 19
7.2 Installation conditions................................................................................ 19
7.3 Installation position ................................................................................... 20
7.4 Mounting the analog amplifier.................................................................... 20
7.4.1 Preparation ................................................................................................ 20
7.4.2 Mounting.................................................................................................... 20
7.4.3 Connector assembly................................................................................... 21
7.4.4 Pin assignment........................................................................................... 31
7.4.5 Pin assignment (parallel operation) ........................................................... 32
7.4.6 Pin assignment (toggling operation) .......................................................... 33
7.5 Examples of connection variants ................................................................ 34
7.5.1 Variants for wiring an input or in parallel operation ................................... 34
7.5.2 Variants with independent circuitry............................................................ 36
7.5.3 Variants with parallel operation of the output stages................................. 37
7.5.4 Information on wiring and circuitry ............................................................ 39
7.5.5 Electrically connecting the analog amplifier ............................................... 40
8 Commissioning��������������������������������������������������������������������������������������� 41
8.1 Parameterization ........................................................................................ 41
8.2 Factory settings.......................................................................................... 42
9 Operation ����������������������������������������������������������������������������������������������� 43

4/48 Analog amplifier RA | Contents
BoschRexrothAG, RE95230-B/2021-12-01
10 Maintenance and repair�������������������������������������������������������������������������� 43
10.1 Cleaning and care ...................................................................................... 43
10.2 Inspection and maintenance ...................................................................... 43
10.3 Repair ........................................................................................................ 43
11 Removal and replacement ���������������������������������������������������������������������� 44
12 Disposal ������������������������������������������������������������������������������������������������� 44
13 Extension and conversion����������������������������������������������������������������������� 44
14 Troubleshooting ������������������������������������������������������������������������������������� 45
15 Technical data ���������������������������������������������������������������������������������������� 46
16 Alphabetical index ��������������������������������������������������������������������������������� 47

RE95230-B/2021-12-01, BoschRexrothAG
About this documentation | Analog amplifier RA 5/48
1 About this documentation
1�1 Validity of the documentation
This documentation is valid for the following product:
• Analog amplifier RA, series 10
This documentation is intended for machine/system manufacturers,
assemblers and service engineers.
This documentation contains important information on the safe and proper
transport, installation, commissioning, operation, maintenance, disassembly and
simple troubleshooting of the product.
▶ Read this documentation completely, in particular chapter2
"Safety instructions" on page8 and chapter 3 "General instructions on
property damage and product damage" on page12 before you start working
with the product.
1�2 Required and supplementary documentation
▶ Only commission the product if the documentation marked with the
booksymbol is available to you and you have understood and observed it.
Table 1: Required and supplementary documentation
Title Document number Document type
Analog amplifier RA, series 10
Contains the permissible technical data,
connections, main dimensions and circuit
diagrams of standard versions.
95230 Data sheet
1�3 Representation of information
Uniform safety instructions, symbols, terms and abbreviations are used throughout
this documentation to ensure safe and proper use of the product. For clarification,
they are explained in the sections below.
1�3�1 Safety instructions
This documentation contains safety instructions in chapter2.6 "Product-specific
safety instructions" on page11 and in chapter3 "General instructions on
property damage and product damage" on page12, as well as before asequence
of actions or an instruction for action involving arisk of personal injury and
property damage. Always follow the measures for danger prevention associated
with the use of this product.

6/48 Analog amplifier RA | About this documentation
BoschRexrothAG, RE95230-B/2021-12-01
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger!
Consequences of non-compliance
▶ Danger prevention measures
•Warning sign: draws attention to the danger
•Signal word: identifies the degree of the danger
•Type and source of danger: indicates the type and source of the danger
•Consequences: describes the consequences of non-compliance
•Precautions: states how the danger can be avoided
Table 2: Hazard classes as defined in ANSI Z535�6
Warning sign, signal word Meaning
DANGER Identifies adangerous situation that will result in death
or serious injury if it is not avoided.
WARNING Identifies adangerous situation that may result in death
or serious injury if it is not avoided.
CAUTION Identifies adangerous situation that may result in minor
to moderate injury if it is not avoided.
NOTICE Property damage: The product or surrounding area may
be damaged.
1�3�2 Symbols
The following symbols indicate notices that are not safety-relevant but increase
understanding of the documentation.
Table 3: Meaning of symbols
Symbol Meaning
If this information is disregarded, the product cannot be used and/or
operated to its full extent.
▶ Single, independent action
1�
2�
3�
Numbered instruction:
The numbers indicate that the actions must be completed in order.

RE95230-B/2021-12-01, BoschRexrothAG
About this documentation | Analog amplifier RA 7/48
1�3�3 Designations
This documentation uses the following designations:
Table 4: Designations
Designation Meaning
RA2-1/10 Analog amplifier RA with two proportional outputs and one switching
output, series 10
As umbrella term for "analog amplifier RA", the designation "product" or "amplifier"
will be used in the following.
1�3�4 Abbreviations
This documentation uses the following abbreviations:
Table 5: Abbreviations
Abbreviation Meaning
ANSI American National Standards Institute is an organization that coordinates
the development of voluntary standards in the United States
DIN Deutsches Institut für Normung (German Institute for Standardization)
EMC Electromagnetic compatibility
EN European Norm (standard)
ISO International Organization for Standardization
RE Rexroth document in the English language

8/48 Analog amplifier RA | Safety instructions
BoschRexrothAG, RE95230-B/2021-12-01
2 Safety instructions
2�1 About this chapter
The product has been manufactured in accordance with generally accepted
engineering standards. There is still, however, adanger of personal injury or
property damage if this chapter and the safety instructions in this documentation
are not observed.
▶ Read this documentation completely and thoroughly before working with
the product.
▶ Keep this documentation in alocation where it is accessible to all users at
all times.
▶ Always include the required documentation when passing the product on to
third parties.
2�2 Intended use
The analog amplifier serves to control up to two proportional solenoids.
The specified control voltage is processed in the amplifier as an input variable.
The analog amplifier provides aregulated electric current as an output variable for
control of the proportional solenoids.
▶ Generally, the analog amplifier must be operated within the operating
ranges specified and approved in the datasheet 95230, particularly with
regard to voltage, current, temperature, vibration, shock and other described
environmental influences.
▶ Its use outside of these specified and approved boundary conditions may result
in danger to life and/or cause damage to components which could result in
sequential damage to the mobile working machine.
▶ Serious personal injury and/or damage to property may occur in case of
non-compliance with the appropriate regulations.
▶ Observe the corresponding IP protection class.
The product is intended only for professional use and not for private use.
Intended use includes having fully read and understood this documentation,
especially chapter 2 "Safety instructions" on page 8.
2�3 Improper use
Any use other than that described as intended use is considered improper.
BoschRexrothAG is not liable for damage resulting from improper use.
The user is solely responsible for any risks arising from improper use.
The following foreseeable forms of faulty usage are also considered improper
(this list is not exhaustive):
• Use outside the operating parameters approved in the datasheet
(unless customer-specific approval has been granted)
• The analog amplifier is not suitable for use in functions relevant to safety.
• Use of the analog amplifier in explosive environments
• Use of the analog amplifier in acorrosive atmosphere

RE95230-B/2021-12-01, BoschRexrothAG
Safety instructions | Analog amplifier RA 9/48
2�4 Personnel qualifications
The activities described in this documentation require basic mechanical,
electronical/electrical and hydraulic knowledge, as well as knowledge of the
associated technical terms. In order to ensure safe use, these activities should only
be performed by skilled personnel or an instructed person under the direction and
supervision of skilled personnel.
Skilled personnel refers to persons who possess the professional training,
knowledge and experience, as well as the understanding of the regulations
relevant to the work to be done that are necessary to recognize possible dangers
and take the appropriate safety measures. Skilled personnel must follow the rules
relevant to their field and have the necessary expert knowledge of mechatronics,
electronics and hydraulics, if applicable.
Expert knowledge means, for instance:
• Being able to read and fully understand electrical circuit diagrams and hydraulic
diagrams, if applicable,
• in particular, fully understanding the relationships with regard to safety
arrangements,
• as well as to carry out the wiring of electronic components correctly and
• to have knowledge of the function and interaction of electronic, mechanical and
hydraulic components.
Only trained and experienced specialists who are adequately familiar with
both the components used and the complete system should implement system
developments or install and commission electronic systems for controlling
hydraulic drives.
BoschRexroth offers you measures supporting training in specific areas.
You can find an overview of the training contents on the Internet at:
www.boschrexroth.com/training.
2�5 General safety instructions
• Observe the country-specific accident prevention and environmental protection
regulations.
• Observe the safety regulations of the country in which the product is
used/operated.
• Use Rexroth products only when they are in good working order.
• Do not install, operate, disassemble or maintain Rexroth products if under the
influence of alcohol, drugs or medication that may affect your reaction time.
• Only use approved accessories and original spare parts from Rexroth in order to
exclude hazards to persons due to unsuitable spare parts.
• Observe the technical data and ambient conditions specified in the product
documentation.
• If unsuitable products are installed or used in applications that are of relevance
to safety, unexpected operating conditions may occur in the application,
which could result in personal injury or property damage. For this reason,
only use the product in safety-relevant applications if this use is expressly
indicated and approved in the product documentation, e.g.in safety-related
parts of acontrol system (functional safety).

10/48 Analog amplifier RA | Safety instructions
BoschRexrothAG, RE95230-B/2021-12-01
• Only commission the product if it has been determined that the end product
(e.g.machinery/system) in which the Rexroth products are installed complies
with the country-specific provisions, safety regulations and standards for the
application.
• Use tools appropriate for the work being performed and wear appropriate
protective clothing to prevent punctures and cuts (e.g.when removing protective
covers, disassembly).
• Setup, installation and operation of the device cannot be monitored. The user is
therefore responsible for the correct use of the product. The valid manufacturer's
specifications for the machine/vehicle must be observed during installation.
• In contrast to digital control units, analog amplifiers only offer limited diagnosis
and monitoring options. The use of an analog amplifier in applications
in which–in the event of anerror – hazardous machine states may arise,
is therefore not permissible without additional external protective measures.
• The safety instructions of the machine/vehicle must be observed.
• If an analog amplifier fails, malfunctions such as unintended actuation or
switching off of one or several solenoids cannot be reliably prevented.
• In emergency situations or if important functions fail, the operating voltage is
to be externally interrupted. To this end, interruption of the electronics’ power
supply has to be provided by means of an emergency stop switch.
The emergency stop switch must be installed in an easily accessible position for
the operator. Safe braking must be ensured when the emergency stop function is
activated.
• Damaged devices must not be commissioned.
• No connection to public supply networks is permitted.
• Mixing up the ground connections at the analog amplifier may impair
functionality.
• If the solenoid output is overloaded (short circuit), the relevant output is not
constantly switched off.
• In case of cable break at one of the external potentiometers, the outputs may still
carry current and are not switched off for all connection variants. In this case,
the error output (pin15) is activated, depending on the connection type.
• To avoid malfunctions, the shield of the lines from and to the potentiometers
is to be connected to the device and/or vehicle ground on one side with low
resistance.
• The analog amplifier must not be wetted by hydraulic fluids, acids or alkalis.
• The suggested circuits do not imply any technical liability for the system on the
part of Rexroth.

RE95230-B/2021-12-01, BoschRexrothAG
Safety instructions | Analog amplifier RA 11/48
2�6 Product-specific safety instructions
The following safety instructions apply to chapters 6 to 14.
WARNING
The analog amplifier RA is not suitable for implementing safety functions!
The RA analog amplifier does not meet the requirements of common
safetystandards. This also applies to basic and proven safety principles.
There is arisk of death or injury!
▶ The amplifier must therefore not be used for safety functions.
▶ The safety of the machine must not depend on the correct functionality
of the amplifier.
Unsecured machine!
Risk of death or serious injury when working on unsecured machines!
Property damage!
▶ Switch off the relevant machine part and secure it against reactivation
according to the parameters of the machine manufacturer.
CAUTION
Improper cable and line routing!
Risk of stumbling and property damage! Improper routing of cables and lines
can cause arisk of stumbling as well as damage to equipment and components,
e.g.due to lines and connectors being torn off.
▶ Always install cables and lines in away that nobody can fall over them,
that they are not bend or twisted, do not chafe on edges and are not guided
through ducts with sharp edges without sufficient protection.
2�7 Personal protective equipment
The personal protective equipment is the responsibility of the user of the product.
Observe the safety regulations in your country.
All pieces of personal protective equipment must be intact.

12/48 Analog amplifier RA | General instructions on property damage and product damage
BoschRexrothAG, RE95230-B/2021-12-01
3 General instructions on property
damage and product damage
The following information applies to chapters 6 to 14.
NOTICE
Environmental pollution due to incorrect disposal!
Careless disposal of the product and the packaging material could lead to
environmental pollution!
▶ Dispose of the product and packaging in accordance with the national
regulations in your country.
Electrical voltage!
Property damage due to electrical voltage!
▶ Always disconnect the voltage supply to the relevant machine/system
part before installing the product and/or connecting or disconnecting the
connector. Protect the machine/system against reactivation.
The warranty exclusively applies to the delivered configuration.
The warranty will be voided if the product is incorrectly installed, commissioned or
operated, or if it is used or handled improperly.

RE95230-B/2021-12-01, BoschRexrothAG
Scope of delivery | Analog amplifier RA 13/48
4 Scope of delivery
The scope of delivery exclusively includes the analog amplifier RA.
Fig� 1: Analog amplifier RA

14/48 Analog amplifier RA | About this product
BoschRexrothAG, RE95230-B/2021-12-01
5 About this product
5�1 Product description
The analog amplifier serves to control up to two proportional solenoids.
The specified control voltage is processed in the amplifier as an input variable.
The analog amplifier provides aregulated electric current as an output variable for
control of the proportional solenoids.
The RA analog amplifier can be used to actuate up to two proportional
solenoids in asingle device (for example atoggling axial piston unit or
avalve section with separate control of the proportional solenoids) or to
actuate two devices independently of each other (for example, two individual
axialpiston units or valves). The use of only one proportional output is possible.
An additional 1 A output is available for aswitching function.
5�2 Features
The electronic analog amplifier offers the following features:
• Optional interdependent locking of the proportional solenoid control
• Voltage supply for external command value potentiometer
• Conditional monitoring of the command value potentiometer for cable break and
short circuit
• Externally controllable switching output
• Error output
• Separately adjustable ramp times for each solenoid
• Overload protection, overvoltage protection, conditional short circuit protection
• Separately adjustable currents Imin (offset) and Imax (gradient) for every solenoid
• Externally adjustable PWM frequency

RE95230-B/2021-12-01, BoschRexrothAG
About this product | Analog amplifier RA 15/48
5�3 Operating modes
The analog amplifier can be used in two operating modes:
• In toggling operation, there is an interlocked control of the proportional
solenoids.
• In parallel operation, two proportional solenoids can be controlled
independently of each other.
For 2 solenoids with interlocked control:
Setting range
Solenoid2
Setting range
Solenoid1
~0.06 x Imax
0 V 4.0 V 8.4 V Ucommand
Imin
~0.8 x Imax
Imax
ISolenoid
Fig� 2: Toggling operation
For 2 solenoids with independent control
Setting range
ISolenoid
Imin
Imax
~0.06 x Imax
~0.8 x Imax
4.0 V Ucommand
8.4 V
Fig� 3: Parallel operation
Imin and Imax control the minimum and maximum current that is applied to the
respective outputs (proportional solenoids).
Imin basically corresponds to an offset (start current from which the solenoid
responds), Imax to the gain (gradient)
As Imax and Imin are added, an output current of almost 200% of the solenoid
control current can be applied to the output of the analog amplifier if Imax and
Imin are both set to the highest value!
Therefore, aproportional solenoid could only react in avery small control range
and achieve almost maximum modulation with very low potentiometer setting.
Toggling operation
Parallel operation

16/48 Analog amplifier RA | About this product
BoschRexrothAG, RE95230-B/2021-12-01
5�4 Assignment and function of the LEDs and setting potentiometer
1 2 3 4
5
6
8
7
10 11
9 12
Fig� 4: Assignment and function of the LEDs and setting potentiometer
1 Potentiometer maximum current Imax1 (PWM current channel 1)
2 Potentiometer minimum current Imin1 (PWM current channel 1)
3 Potentiometer downwards ramp tdown1 (PWM current channel 1)
4 Potentiometer upwards ramp tup1 (PWM current channel 1)
5 Potentiometer maximum current Imax2 (PWM current channel 2)
6 Potentiometer minimum current Imin2 (PWM current channel 2)
7 Potentiometer downwards ramp tdown2 (PWM current channel 2)
8 Potentiometer upwards ramp tup2 (PWM current channel 2)
9 PWM current channel 2 (I2 - yellow LED)
10 Power (operating display - green LED)
11 Error (error display - red LED)
12 PWM current channel 1 (I1 - yellow LED)
The brightness of LEDs I1 and I2 depends on the strength of the output current
and thus serves arough visual control.
The ramps control the time required by the output current to reach anew
value. The control range is between 100 ms and 10 s at maximum change from
Imin to Imax.
For the potentiometers, the following applies in general: Clockwise rotation means
an increase in the setting (longer ramp time or higher current).

RE95230-B/2021-12-01, BoschRexrothAG
About this product | Analog amplifier RA 17/48
5�5 Identification of RA
The product is to be identified by means of the material number (1) on the
analog amplifier.
1
Fig� 5: Material number RA

18/48 Analog amplifier RA | Transport and storage
BoschRexrothAG, RE95230-B/2021-12-01
6 Transport and storage
Check the analog amplifier for transport damage. If there are obvious signs of
damage, please inform the transport company and BoschRexroth immediately.
If the analog amplifier is dropped, continued use is not permissible because
unseen damage may affect its reliability.
6�1 Transporting and storing the analog amplifier
• Shock resistance:
Transport shock (IEC60068-2-27) 3x in each direction (positive/negative) and
15g / 11 ms in each axis.
• Store analog amplifiers at an average relative humidity of 60% and at
atemperature between -10°C and +30°C.
• After astorage time of more than 5years, the analog amplifier must be checked
by the manufacturer before use.
Requirements

RE95230-B/2021-12-01, BoschRexrothAG
Installation | Analog amplifier RA 19/48
7 Installation
Prior to installation, the following documents should be to hand:
• Data sheet of the product (contains the permissible technical data,
main dimensions and circuit diagrams of standard versions)
7�1 Unpacking
NOTICE! Danger due to electrostatic discharge!
When unpacking the analog amplifier, there is adanger of damage to the electronic
components of the analog amplifier due to electrostatic discharge.
▶ When unpacking, protect the analog amplifier against electrostatic discharge;
information on the protection of the analog amplifier against electrostatic
discharge (ESD) can be found in the respective data sheet
(Table 1 "Required and supplementary documentation" on page 5).
▶ Remove the packaging from the analog amplifier.
▶ Check the analog amplifier for transport damage and completeness,
see chapter4 "Scope of delivery" on page13.
▶ Dispose of the packaging in accordance with the regulations in your country.
7�2 Installation conditions
▶ Do not install the control unit near parts which generate considerable heat
(e.g.exhaust).
▶ Radio equipment and mobile telephones must not be used in the driver's cab
without asuitable antenna or near the control electronics.
▶ A sufficiently large distance to radio transmission systems must be maintained.
▶ All connectors must be unplugged from the electronics during electrical
welding or painting operations.
▶ The control units must not be electrostatically charged, e.g.during painting
operations.
▶ The control unit will heat up beyond normal ambient temperature during
operation. To avoid danger caused by high temperatures, it should be protected
against contact.
▶ Standing and permanently running water is not permissible in the area
of the seal.

20/48 Analog amplifier RA | Installation
BoschRexrothAG, RE95230-B/2021-12-01
7�3 Installation position
The analog amplifier must be installed so that the connector is positioned
vertically downwards.
The cable must be routed so that it lies completely or partially below the amplifier
connection (see Fig. 6).
The IP65 type of protection is only achieved in the shown installation position in
combination with asealing of the connector relative to the wire harness sleeve.
Any ingress of water into the analog amplifier by way of the wire harness must be
avoided by routing the wire harness accordingly.
Fig� 6: Installation position analog amplifier
7�4 Mounting the analog amplifier
7�4�1 Preparation
1� Use the material number on the sticker of the packaging unit or directly onthe
analog amplifier to check whether the correct analog amplifier is available,
see chapter 4 "Scope of delivery" on page13.
2� Compare the material number with the details in the order confirmation.
If the material number of the analog amplifier does not match the one in the
order confirmation, contact your local contact person for clarification.
You can find their contact information at
https://addresses.boschrexroth.com
7�4�2 Mounting
The RA analog amplifier has mounting lugs for assembly.
Use M6 screws (no countersunk head). Washers are absolutely necessary.
Tighten the screws with atorque of 4 Nm.