Electric Drives and Controls Hydraulics Linear Motion and Assembly echnologies Pneumatics ervice Axial Piston Variable Pump KVA E 92250/02.07 /16 eplaces: 04.06 echnical data sheet eries 6 izes 55... 107 Nominal pressure 300 bar Peak pressure 350 bar for commercial vehicles, open circuit Contents Ordering Code / tandard Program 2 echnical Data 3 D - Pressure Control with Load ensing 6 EP - Electric Control with Proportional olenoid 7 Unit Dimensions, ize 55 8 Unit Dimensions, ize 80 10 Unit Dimensions, ize 107 12 Installation Notes 14 General Notes 15 Features Variable pump with axial tapered piston rotary group of bent axis design. Designed especially to meet the requirements of commercial vehicles. he output flow is proportional to the drive speed and pump displacement and is steplessly variable between maximum and zero (q v max to q v min = 0). Favourable power/weight ratio, small overall dimensions, optimum efficiency and economic design elf aspirating, for open circuit operation Flange and shaft designed for direct mounting on truck gearbox PO s Further Informations: Fixed pump KFA E 91501 designed especially to meet the requirements of commercial vehicles.
2/16 Bosch exroth AG KVA E 92250/02.07 Ordering Code / tandard Program KVA7V O / 6 3 M E K 64 01 02 03 04 05 06 07 08 09 10 11 Axial piston unit 01 Bent axis design, variable, nominal pressure 300 bar, peak pressure 350 bar, for commercial vehicles (truck) KVA7V Operation mode 02 Pump in open circuits O ize 03 Displacement V g max in cm 3 55 80 107 Control devices 55 80 107 Pressure control with load sensing D 04 Electric control with proportional solenoid U = 24 V positive characteristics EP2 negative characteristics EP4 eries 05 6 Index 06 3 Direction of rotation Viewed on shaft end clockwise 07 counter-clockwise L eals 08 FKM (2 back to back shaft seals) M haft end 09 plined shaft similar DIN IO 14 (for truck use) E Mounting flange 10 pecial flange IO 7653-1985 (for truck use) K ervice line ports 11 hreaded port A(B), rear 64 l = available = not available
E 92250/02.07 KVA Bosch exroth AG 3/16 echnical Data Hydraulic fluid Before starting project planning, please refer to our data sheets E 90220 (mineral oil) and E 90221 (environmentally acceptable hydraulic fluids) for detailed information regarding the choice of hydraulic fluids and conditions of use. If environmentally acceptable hydraulic fluids are being used, the limitations regarding technical data and seals mentioned in E 90221 must be observed. When ordering please indicate the used hydraulic fluid. Attention: For the operation with water-containing HF-fluids the variable pump KVA is not suitable. Viscosity range We recommend that a viscosity (at operating temperature) for optimum efficiency and service life purposes of ν opt = opt. operating viscosity 16...36 mm 2 /s be chosen, taken the tank temperature (open circuits) into account. Limits of viscosity range he following values apply in extreme cases: ν min = 5 mm 2 /s short term (t < 3 min.) at max. permitted temperature t max = 115 C. ν max = 1600 mm 2 /s short term (t < 3 min.) with cold start (p < 30 bar, n 1000 rpm, t min = -25 C). Note that the maximum hydraulic fluid temperature of 115 C must not be exceeded locally either (e.g. bearing area). he temperature in the bearing area is - depending on pressure and speed - up to 12 K higher than the average case drain temperature. his axial piston unit can not be operated in a temperature range of less than -25 C. election diagram -40 1600-20 0 20 40 60 80 100 1600 1000 600 400 viscosity ν in mm 2 /s 200 100 60 40 20 10 5 5-40 -25-10 0 10 30 50 70 90 115 temperature t in C t min = -25 C VG 22 VG 32 VG 46 VG 68 VG 100 hydraulic fluid temperature range Details regarding the choice of hydraulic fluid 36 16 n opt. t max = +115 C he correct selection of hydraulic fluid requires knowledge of the operating temperature in relation to the ambient temperature, in an open circuit the tank temperature. he hydraulic fluid should be selected so that within the operating temperature range, the operating viscosity lies within the optimum range (ν opt ) (see shaded section of the selection diagram). We recommend that the highest possible viscosity range should be chosen in each case. Example: At an ambient temperature of C an operating temperature of 60 C is set in the circuit. In the optimum viscosity range (ν opt ; shaded area) this corresponds to the viscosity classes VG 46 or VG 68; to be selected: VG 68. Please note: he case drain temperature, which is affected by pressure and rotational speed, is always higher than the tank temperature. At no point in the system may the temperature be higher than 115 C. If this cannot be achieved due to unusual operating parameters or high ambient temperatures, please contact us. Filtration he finer the filtration, the cleaner the fluid and the longer the service life of the axial piston unit. o ensure proper function of the axial piston unit, the hydraulic fluid must have a cleanliness level of at least 20/18/15 according to IO 4406. At very high hydraulic fluid temperatures (90 C to max. 115 C), a cleanliness level of at least 19/17/14 according to IO 4406 is required. Please contact us, if these cleanliness levels cannot be achieved.
4/16 Bosch exroth AG KVA E 92250/02.07 echnical Data Operating pressure range Inlet Pressure at port he minimum inlet pressure depends on the speed. he following limits may not be exceeded. p abs min 0,8 bar he maximum pressure p abs max also depends on speed (see succeeding diagram). Minimum inlet pressure at suction port with increased speed In order to avoid damage of the pump a minimum inlet pressure at the suction port must be assured. he minimum inlet pressure is related to the rotational speed and the displacement of the variable pump. n nmax 1 peed 1,5 1,4 1,3 1,2 1,1 1,0 0,9 0,8 0,6 0,7 0,8 0,9 1,0 V g Displacement V g max 2,0 1,9 1,8 1,7 1,6 1,5 1,4 1,3 1,2 1,1 1,0 0,9 0,8 Inlet pressure pabs in bar emperature range he FKM shaft seal ring is admissible for a case temperature range from -25 C bis +115 C. Note: his axial piston unit can not be operated in a temperature range of less than -25 C. Direction of flow Direction of rotation, viewed on shaft end clockwise counter-clockwise to B to A Note: max. permissible speed n max perm. (speed limit, see page 5) min. and max. permissible inlet pressure at port Outlet Maximum pressure at port A or B (pressure specifications in according to DIN 24312) Nominal pressure p N 300 bar Peak pressure p max 350 bar Case drain he case of the pump is connected to the inlet port. A separate case drain is therefore not required (purge port is plugged) Exception: When using the D control a separate drain line from port to the tank is mandatory (not required for EP control).
E 92250/02.07 KVA Bosch exroth AG 5/16 echnical Data able of values (theoretical values, without efficiencies and tolerances; values rounded) ize 55 80 107 Displacement V g max cm 3 54,8 80 107 peed max. 1 ) at V g max n max1 rpm 2500 2240 2150 at V g < 0,74 V g max (see diagram, page 4) n max2 rpm 3400 3000 2900 peed max. 2 ) n max perm. rpm 3750 3350 3200 Flow at n max 1 and V g max q v max 1 L/min 137 179 230 Power at q v max 1 and Δp = 300 bar P max 1 kw 68 90 115 orque at V g max and Δp = 300 bar Nm 261 382 510 Mass moment G Nm 21 28,5 41 Moment of inertia (of the rotating parts) J kgm 2 0,0034 0,0064 0,0102 Filling capacity V L 0,6 0,8 1,2 Mass (approx.) m kg 16 20 24 1 ) he values shown are valid for an absolute pressure p abs = 1 bar at the suction port»«and when operated on mineral fluid with a specific mass of 0,88 kg/l. 2 ) Maximum speed (speed limit) for an increase in the inlet pressure p abs at the suction port and V g < V g max Determining the size Flow q v = V g n η v 1000 L/min V g = Displacement per revolution in cm 3 Δp = Differential pressure in bar orque = Power P = V g Δ p 20 π η mh 2 π n = q v Δp 60000 600 η t Nm kw n = speed in rpm η v = Volumetric efficiency η mh = Mechanical-hydraulic efficiency η t = Overall efficiency Permissible axial loading on the drive shaft he values given are maximum values and do not apply to continous operation. For drives with radial loading (pinion, V-belt drives), please contact us! ize 55 80 107 when stopped or when axial piston unit working in pressureless conditions ± F ax max N 0 0 0 Axial force / operating pressure F ax + + F ax zul. N/bar 8,7 10,6 12,9 F ax zul. N/bar -66-86 -103 When considering the permissible axial force, the force-transfer direction must be taken into account: F ax max = increase in service life of bearings + F ax max = reduction in service life of bearings (avoid if at all possible) Accessories for KVA For the KVA-pump the following accessories are available from exroth: Coupling flange, used in pump operation via a joint shaft (see E 95001) uction pipe, in all variations (see E 95004) Adaption flange, for KVA-mounting in unfavourable mounting conditions (on enquiry)
6/16 Bosch exroth AG KVA E 92250/02.07 D - Pressure Control with Load ensing Function of the pressure control Characteristic D he pressure control keeps the pressure in a hydraulic system constant within its control range even under varying flow conditions. he variable pump only moves as much hydraulic fluid as is required by the actuators. If the operating pressure exceeds the setpoint set at the integral pressure control valve, the pump displacement is automatically swivelled back until the pressure deviation is corrected. In zero pressure non-running condition, the pump is swivelled to its starting position V g max by means of the control spring. etting range for pressure control 80 to 320 bar tandard setting: 300 bar Note: Any pressure relief vlave included in the circuit to limit the max. pressure must be set to a cracking pressure at least 20 bar above the pressure control setting. Operating pressure pb in bar 350 50 V g min max min Circuit diagram D Displacement V g max max. 10 bar he pressure control is superimposed on the load sensing valve, i.e. the load sensing function operates below the set pressure. Load sense function he load sensing control is a flow control option that operates as a function of the load pressure to regulate the pump displacement to match the actuator flow requirement. he flow depends here on the cross section of the external sensing orifice (1) fitted between the pump outlet and the actuator. he flow is independent of the load pressure below the pressure cut-off setting and within the control range of the pump. he sensing orifice is usually a separately arranged load sensing directional valve (control block). he position of the directional valve piston determines the opening cross section of the sensing orifice and thus the flow of the pump. he load sensing control compares pressure before and after the sensing orifice and maintains the pressure drop across the orifice - and therefore the pump flow - constant as a function of the orifice size. If the differential pressure Dp increases, the pump is swivelled back towards V g min and, if the Dp decreases the pump is swivelling out towards V g max until the pressure drop across the sensing orifice in the valve is restored. Δp orifice = p pump p actuator etting range for Δp: 19... 40 bar tandard setting: 30 bar he stand-by pressure in zero stroke operation (sensing orifice plugged) is slightly above the p setting. (1) he sensing orifice (control block) is not included in the pump supply. Zero stroke operation Vg min Vg max A (B) he standard pump unit is designed for intermittent constant pressure operation. hort-term operation at zero stroke (< 10 min.) is permissible up to a operating pressure p max = 300 bar at a tank temperature of 50 C. Note: When using the D control a drain line is mandatory from the port to tank to maintain thermal stability. When ordering, state in clear text: - etting of the pressure control - Δp - setting of the load sensing function (If there is no clear specification, pump will be delivered with standard setting, see above.) A1 1 (1)
E 92250/02.07 KVA Bosch exroth AG 7/16 EP - Electric Control with Proportional olenoid With the Electric control with proportional solenoid, the pump displacement is adjusted proportionally to the solenoid current, resulting in a magnetic control force, acting directly onto the control spool that pilots the pump control piston. Circuit diagram EP2 (ize 55) EP2 - tarting position in unpressurised state at V g min. EP4 - tarting position in unpressurised state at V g max. Charactreristic EP A (B) 800 700 EP2 Vg max Vg min A1 Control current I in ma 600 500 400 300 200 100 EP4 EP4 (ize 107) 1 0 0,2 0,4 0,6 0,8 1,0 V g min Displacement V g max Note: For submerged in-tank installation when using the EP control, only the mineral hydraulic fluids can be used with the fluid temperature limited to 80 C. Vg min Vg max A (B) A1 1 o control the proportional solenoids the following electronic amplifier and controller are available (also as to the Internet under www.boschrexroth.com/mobile-electronic): BODA controller C (E 95200) and application software Analog amplifier A (E 95230) By using an proportional amplifier control of swivel time is also possible. echnical data of solenoids EP2 EP4 izes 55 107 Voltage 24VDC +20% 24VDC +20% Control current tart of control V g min 200 ma V g max 200 ma End of control V g max 600 ma V g min 600 ma Limiting current 0,77 A 0,68 A Note he spring centering in the pilot control unit is not a safety device hrough contamination in the control unit e.g. in hydraulic fluid, wear particles, or particles out of a system the valve spool can get stuck in an undefined position. In this case, the pump flow does not follow the command inputs of the machine operator anymore. Make sure that a proper emergency shut down function can bring the driven machine movements to a safe position immediately (e.g. stop). Maintain the specified cleanliness level 20/18/15 (<90 C) or 19/17/14 (>90 C) to IO 4406. Nominal resistance (at 20 C) 22,7 Ω 24,2 Ω Dither frequency 100 Hz 100 Hz Duty cycle 100 % 100 % ype of protection IP 65 IP 54 Connector Hirschmann to DIN EN 175 301-803-A / IO 4400 AMP- Junior imer 2 pin
8/16 Bosch exroth AG KVA E 92250/02.07 Unit Dimensions, ize 55 Before finalizing your design, please request approved installation drawing. Dimensions in mm. D Pressure control, with load sensing 267 214 156 130*) 15 80-0.03-0.05 ø80 10*) 32 76 91 180 110 120 122 9 39 12 30' Y 120 ø13 110 ± 0.4 80 105 113 1 229 232 242 conter-clockwise rotation clockwise rotation 12 40 105 A B G3/4 14 17 G1 1 1 27.5 27.5 118 *) center of gravity
E 92250/02.07 KVA Bosch exroth AG 9/16 Unit Dimensions, ize 55 EP2 Electric control, with proportional solenoid Before finalizing your design, please request approved installation drawing. Dimensions in mm. 276 Note: he position of the plug can be changed by turning the solenoid body. 131 1 Y Note the following procedure: 1. Loosen the fastening nut (1) 2. urn the magnet body (2) to the desired position 3. ighten the fastening nut ightening torque of fastening nut: 5+1 Nm (width across flat 26, double hexagon DIN 3124) (2) (1) conter-clockwise rotation clockwise rotation A 1 1 A B 1 haft end E plined shaft similar DIN IO 14 8x32x35 26.1 28 9.5 12 36.8 groove for retaining ring 55 35x1.5 DIN 471 Ports A, B ervice line ports (high pressure series) DIN IO 228 G 3/4, 16 deep 330 Nm 2 ) uction port DIN IO 228 G 1; 18 deep 480 Nm 2 ) Case drain (only D) IO 6149 M12x1,5; 12 deep 50 Nm 2 ) Gauge port - high pressure 3 ) IO 6149 M10x1; 8 deep 30 Nm 2 ) 1 Gauge port - suction pressure 3 ) IO 6149 M10x1; 8 deep 30 Nm 2 ) Air bleed 3 ) IO 6149 M18x1,5 60 Nm 2 ) Port for Dp control (load sensing) IO 11926 7/16-20UNF-2B; 11,5 deep 40 Nm 2 ) 1 ) centering bore according to DIN 332 (thread according to DIN13) 2 ) please observe the general notes for the max. tightening torques on page 15. 3 ) plugged M12x1.75 1 ) 2 ) ø8.1 ø34.9-0.1
10/16 Bosch exroth AG KVA E 92250/02.07 Unit Dimensions, ize 80 D Pressure control, with load sensing Before finalizing your design, please request approved installation drawing. Dimensions in mm. 289 236 178 142*) 15 116 126 128 80-0.05 ø80-0.03 36 120 80 105 128 9 37 12 30' 12*) 86 103 195 Y ø13 117 ± 0.4 1 248 252 263 conter-clockwise rotation clockwise rotation 12 40 105 A B G1 14 18 G1 1/4 1 1 30 30 128 *) center of gravity
E 92250/02.07 KVA Bosch exroth AG 11/16 Unit Dimensions, ize 80 haft end Before finalizing your design, please request approved installation drawing. Dimensions in mm. E plined shaft similar DIN IO 14 8x32x35 26.1 28 9.5 M12x1.75 1 ) 2 ) ø8.1 12 36.8 groove for retaining ring 55 35x1.5 DIN 471 ø34.9-0.1 Ports A, B ervice line ports (high pressure series) DIN IO 228 G 1, 18 deep 480 Nm 2 ) uction port DIN IO 228 G 1 1/4; 20 deep 720 Nm 2 ) Case drain (only D) IO 6149 M12x1,5; 12 deep 50 Nm 2 ) Gauge port - high pressure 3 ) IO 6149 M10x1; 8 deep 30 Nm 2 ) 1 Gauge port - suction pressure 3 ) IO 6149 M10x1; 8 deep 30 Nm 2 ) Air bleed 3 ) IO 6149 M18x1,5; 60 Nm 2 ) Port for Dp control (load sensing) IO 11926 7/16-20UNF-2B; 11,5 deep 40 Nm 2 ) 1 ) centering bore according to DIN 332 (thread according to DIN13) 2 ) please observe the general notes for the max. tightening torques on page 15. 3 ) plugged
12/16 Bosch exroth AG KVA E 92250/02.07 Unit Dimensions, ize 107 D Pressure control, with load sensing Before finalizing your design, please request approved installation drawing. Dimensions in mm. 307 250 15 191 172*) 80 ø80-0.03-0.06 40 132 134 120 80 105 138 9 43 12 30' 14*) 91 110 206 ø13 124 ± 0.4 259 264 282 13 40 105 G1 G1 1/4 124 1 Y conter-clockwise rotation clockwise rotation A B 14 1 19.5 1 31.5 31.5 139 *) center of gravity
E 92250/02.07 KVA Bosch exroth AG 13/16 Unit Dimensions, ize 107 EP4 Electric control, with proportional solenoid Before finalizing your design, please request approved installation drawing. Dimensions in mm. 306 178 Y 1 conter-clockwise rotation clockwise rotation A B A1 1 A1 1 haft end E plined shaft similar DIN IO 14 8x32x35 26.1 28 9.5 M12x1.75 1 ) 2 ) ø8.1 12 36.8 groove for retaining ring 55 35x1.5 DIN 471 ø34.9-0.1 Ports A, B ervice line ports (high pressure series) DIN IO 228 G 1, 18 deep 480 Nm 2 ) uction port DIN IO 228 G 1 1/4; 20 deep 720 Nm 2 ) Case drain (only D) IO 6149 M12x1,5; 12 deep 50 Nm 2 ) Gauge port - high pressure 3 ) IO 6149 M10x1; 8 deep 30 Nm 2 ) 1 Gauge port - suction pressure 3 ) IO 6149 M10x1; 8 deep 30 Nm 2 ) Air bleed 3 ) IO 6149 M18x1,5; 60 Nm 2 ) Port for Dp control (load sensing) IO 11926 7/16-20UNF-2B; 11,5 deep 40 Nm 2 ) 1 ) centering bore according to DIN 332 (thread according to DIN13) 2 ) please observe the general notes for the max. tightening torques on page 15. 3 ) plugged
14/16 Bosch exroth AG KVA E 92250/02.07 Installation Notes General During commissioning and operation, the axial piston unit must be filled with hydraulic fluid and air bled. his is also to be observed following a relatively long standstill as the system can be drained through the hydraulic lines. he case is connected to the inlet port. A seperate case drain to tank is not required. Exception: version with D control. When using the D control a drain line from port to tank is mandatory to maintain thermal stability. In all operating conditions, the suction and drain line must flow into the tank below the minimum fluid level. he minimum suction pressure at port must not fall below 0,8 bar absolute. Installation position As to the examples mentioned below. Installation below the tank (standard) Pump below minimum fluid level in tank. ecommendation installation position: 1 and 2. Installation above the tank Pump above minimum fluid level in tank. - Note: - max. perm. suction height h max = 800 mm - min. perm. suction pressure at port 1 2 3 4 1 A1 L 2 L 2 1 A1 Installation position Air bleed Filling Installation position Air bleed Filling 1 3 (L 2 ) (L 2 ) 2 1 4 1 (L 2 ) (L 2 )
E 92250/02.07 KVA Bosch exroth AG 15/16 General Notes he KVA pump is designed to be used in open circuits. Project planning, assembly and commissioning of the pump require the involvement of trained personnel. he working and functional ports are only designed to accommodate hydraulic piping. here is a danger of burns from the pump and especially the solenoids during and shortly after operation. uitable safety precautions, e.g. protective clothing plan. he characteristic curve may shift depending on the operating status (operating pressure, fluid temperature) of the pump. ightening torques: - he tightening torques specified in this data sheet are maximum values and may not be exceeded (maximum value for screw thread). Manufacturer specifications for the max. permissible tightening torques of the used fittings must be observed! - For DIN 13 fastening screws we recommend checking the tightening torque individually according to VDI 2230 Edition 2003. he data and information contained herein must be adhered to.
16/16 Bosch exroth AG KVA E 92250/02.07 Bosch exroth AG Hydraulics Product egment Axial Piston Units Elchingen Plant Glockeraustraße 2 89275 Elchingen, Germany Phone +49 (0) 73 08 82-0 Facsimile +49 (0) 73 08 72 74 info.brm-ak@boschrexroth.de www.boschrexroth.com/axial-piston-pumps his document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch exroth AG. It may not be reproduced or given to third parties without its consent. he data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. he 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. ubject to change.