RE 29 771/09.

97

RE
Programmable electronic remote control
29 771/09.97
type THE 6, series 2X
Replaces: 03.97

The THE 6 electronic remote controls are extremely reliable

units which are suitable for operation in adverse conditions.
They produce power currents for the direct supply of solenoids.
The THE 6 electronic remote controls are easily connected and
enable a quick introduction into service.

Features:
– Programming of characteristic curves and ramps for each
power output
– Possible matching to solenoid data
– High mechanical robustness (built from the components of
the remote control type TH6)
– High reliability of the Opto sensors with constant self-
calibration (no wear, no drift)
– Maximum protection from electro-magnetic interferences
– High reliability of the control electronics which are
completely integrated into metal housing of the remote
control unit
– Protection of control electronics from:
• reversal of polarity Remote control type 4THE6
• short circuit
• interruption of voltage circuit (e.g. cable break)
– Logic outputs to relay call-up
– Help with diagnosis
– Manual operation of 1, 2 or 3 axes
– Foot operation of 1 axis
– Possibility to double the power outputs which are
controlled by one axis (except the 3rd axis)

Remote control type 2THE6 R Remote control type 2THE6 Programming console type PROG

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Functional description

1. Function principle 3. Programming

The THE6 remote controls were developed for the direct control
of electrically pilot operated proportional actuators according to
programmable parameters
The operation of the lever or the pedal of the THE6 causes the
generation of a small proportional electric signal via the optical
measurement and evaluation of the lever or pedal deflection.
This signal is processed by the micro-processor of the controlled
axis and, depending on the parameters stored during the
programming, is converted into one or more electrical power
signals. The power signals are used for the direct control of the
connected actuators.
2. Installation
The unit must be connected to a direct voltage source (battery or
power supply unit). The actuators to be controlled must be
directly electrically connected to the multi-pin connector of the
remote control.
Each power output of the THE6 remote control can be controlled
with its own parameters.
Parametering determines two control characteristic curves the
allocated ramps and the parmaters for the solenoids to be
controlled. Switching from one characteristic curve to another is
achieved via a so-called fine control switch that is switched
between the mass of the machine and the "fine control input" of
the remote control. Each control characteristic curve may be
determined through 5 main points. Different ramp values "Up"
and "Down" are allocated to each control curve.
The remote control type THE6 A… has additional "secondary
outputs" (except the 3rd axis), which operate parallel to the "main
outputs". Each of these additional power outputs may have its
own parametering.
Unless ordered otherwise the THE6 remote controls are
supplied with standard parametering (see page 5).

Because of the programming of the control parameters the

THE6 remote control can be suitably matched to each actuator
to be controlled.

The programming is carried out at the factory and can be altered

on site with the programming console PROG or with a PC.
These aids enable the recording and alteration of the parameters
and at the same time are a help for diagnosics.

Technical data (for applications outside these parameter, please consult us!)

Life expectancy - 4THE 6 5•106 switching operations

- 2THE 6 3•106 switching operations
- 2THE 6R 3•106 switching operations
Operating torque Start End
- 4THE 6 Nm 0.3 0.7
- 2THE 6 Nm 0.8 1.6
- 2THE 6R Nm 4.7 8.9
Max. permissible - 4THE 6 Nm 80
operating torque - 2THE 6 Nm 80
- 2THE 6R Nm 80 (120 through connected lever)
Weight - 4THE 6 kg 3.3
- 2THE 6 kg 2.3
- 2THE 6R kg 3.7
Max. permissible - storage °C – 40 to + 90
temperature range - operation °C – 20 to + 80
Protection IP 65
Tested under the influence of mechanical oscillations

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 RE 29 771/09.97

Electrical data (for applications outside these parameters, please consult us!)
Supply voltage VCC (=) 12 or 24 (limit values 8 to 32)
Proportional power output
- max. current A 2.2 (1.8 on 3rd axis)
- frequency Hz 100, 150, 200
Logic output - max. current A 2.2 (1.8 on 3rd axis)
Grip switch data for the 4THE6
• Switching capacity
- Direct voltage 12V/5A resistive 300 000 cycles
24V/5A resistive 150 000 cycles
12V/1.25A inductive 200 000 cycles
24V/1.25A inductive 200 000 cycles
- Alternating voltage 250V/5A resistive 250 000 cycles
250V/5A inductive 100 000 cycles
• Contact resistance mΩ < 20
• Isolation resistance at 500 V MΩ > 10 000
• Permissible loading with short time current 100 A, 30 ms
• Switching on/off with low loads
- minimum voltage V 10
- minimum current mA 30

Tested under the influence of electro-magnetic interferences

Application guidelines

– Select the same power supply for the THE6 and the solenoids which are to be connected, i.e. 12V solenoids for
12V applications and 24V solenoids for 24V applications.

– If electrical arc welding is to be performed on the machine or vehicle, then the remote control has to be isolated from the on-
board net.

– Ensure that there is adequate distance away from transmitters, so that the magnetic field being aquired by the remote control
is limited to 50 V/m. For higher magnetic fields, please contact MANNESMAN REXROTH S.A.

– Do not connect output cables with the power supply.

– After correcting a fault, reset the remote control by switching the power supply off.

– An emergency off for the power supply is to be provided. Please note: when the remote control power supply is switched off
the output currents are switched off without a ramp.

– Do not fit free-wheel diodes in the power cables that connect the solenoids with the THE6.
If the cables are interruped (e.g. by relays), then suitable protective circuitry has to be provided (see RE 29771-02-B, cabling).

– The machine inductive loads are to be fitted with free-wheel diodes.

– When starting the BKM of a mobile machine the THE6 remote control must not be switched on.

– Please take the instructions which are contained within the following data sheets into account before installing the THE6
remote control into a machine :

• RE 29771-02-B Electronic remote control THE6 - wiring,

• RE 29771-01-B Commissioning a prototype machine fitted with a THE6 remote control,

• RE 29771-03-B Using the DIAG diagnosics console

,
• RE 29771-04-B Using the PROG programming console.

– Do not use in hazardous areas. (Danger of explosion).

– When in use the programming tools must be separated from the remote control, this is to ensure that the parameters are protected.

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RE 29 771/09.97

Variations of ergonomic grip

TT ST VT
Single E-contact
to the front

Single E-contact
on the top

- Without E-contact - single E-contact on top - Double E-contact

with rocker switch
Double E-contact
with rocker switch

YT YU

- Double E-contact - Double E-contact with

with rocker switch rocker switch

- Single E-contact on top - Single E-contact on top

- Single E-contact to the

front

Grip electrical symbols

ST VT YT YU
yellow black grey yellow black grey yellow black grey white

green red blue green red blue green red blue brown

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Programming of an operating curve

The control curves of each output can be determined through 2
to 5 points whereby these reference points in the X-axis are
100% calculated through percentage values of the lever angle and in
the Y-axis through percentage current values.
Yf
If the programmed value for Yf is not 100 %, the programme
automatically carries out a jump to 100 % after reaching the
value for Yf.
Y3 Parametering of the control output curve:
Jump at start : Xd = 10 Yd = 20
Y1=Y2 Jump at end : Xf = 85 Yf = 85
Number of segements: 4
Yd
Input of the segements
Point no. 1 : X1 = 40 Y1 = 35
Xd X1 X2 X3 Xf 100% Point no. 2 : X2 = 55 Y2 = 35
Point no. 3 : X3 = 60 Y3 = 55

Programming of a ramp
Each control curve has two ramp values. One value (ramp "Up")
determines the maximum acceleration value; the other value
t tR t tF
(ramp "Down") determines the maximum deceleration value.
IImax The ramp times result from the basic time of 28 ms, multiplied by
max
the programmable ramp factor. The sequence of the maximum
current equals :
Answer
Current

Command
Imax / tR bzw. Imax / tF
value
Ramp parametering :
Acceleration ramp : tR = 100 • 28ms
Deceleration ramp : tF = 120 • 28ms
Time
Max. current : Imax = 2.0A

Standard programming

% If there are no special request for parametering when a THE 6

remote control is ordered then a remote control with standard
parametering is supplied.
Yf
This standard parametering is suitable for the control of the
solenoids of the pressure reducing valves FT DRE 2K 12V,
Current

DRE4 12V (max. current : 1.8 A).

Yd

Standard parametering of the operating curve :

Jump at start : Xd = 10 Yd = 40
Jump at end : Xf = 100 Yf = 100

Xd Xf % Number of segements : 1
Lever angle
%

100% 1,8A

Command Standard parametering of the ramps :

Current

value Answer
Ramp Up : tR = 10
Ramp Down : tF = 10

35% Max. current : Imax = 1,8

Min. current : Imin = 35

Time

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RE 29 771/09.97

Possible programming of the operating curves

Example: 4THE6 A (2 axes, 4 main outputs, 4 auxiliary outputs, 16 operating curves)

on on Marked output Axis Internal

on housing Opto sensor
Fine control Fine control 1-1 1 1
off off 2-2 2 2
1-2 1 2
2-1 2 1
2-2
on off off on

Main axis
1-2 1-1

Auxiliary axis

on off off on
2-1

off off
Fine control Fine control

Each arrow tip represents an electrical output. The diagrams

on on
The horizontal and vertical parallel arrows represent the division
of the control axes which offer the THE6 models with additional
electrical outputs ("auxiliary outputs").
illustrate the parametering allocated to the outputs. Each output
has two diagrams allocated, i.e. the parametering "fine control
OFF" and the parametering "fine control ON".
The THE6 remote controls are intended for the control of
pressure reducing valves types FT DRE2K and DRE4K.
Through appropriate programming the THE6 can be matched for
the control of other solenoids (1 type per axis).

Circuit diagram (connection example: 4THE 6 A)

4THE6

Plug

PCTHE6 Machine cable set

Error display

MANNESMAN
Dead man switch
REXROTH

+ PROG Safety input

PROG
- OK

PC Fine control 1

Console for Fine control 2

Programming and + -
diagnosis
Battery
Fuse (12V or 24V)

When in operation the programming tools must be isolated from the remote control so that the parameters are protected.

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 RE 29 771/09.97

Terminal connection: 2THE6

AMP plug 1 2 3 4 5 6 7
A
Cable colour Terminal Terminal Designation B
AMP plug sealed plug C
White 1A 1 ground D
Brown 3A 3 battery +
Green 6A 5 fine control 31 20
21
30 8
Grey 1B 7 safety input 19 9
Yellow 4B 10 dead man input contact Sealed plug 18 2 10
22
29 7 3
Black 6B 12 fault display output DEUTSCH-HDB 17 1 11
White-green 7B 13 axis 1, main output 2 28 6 4 23
16 5 12
White-brown 1C 14 axis 1, common main return current 15 13
Pink 2C 15 axis 1, main output 1 27 14 24
26 25
Blue 3C 16 axis 1, common main return current * Type 2.2
White-yellow 6C 19 diagnosis output contains an automatic
Red 3D 23 axis 1, auxiliary output 1 locking of the parametering. This locking
Violet 4D 24 axis 1, auxiliary output 2 starts when switching off the
White-grey 6D 26 parameter key* PCTHE6/PROG console tools.

Terminal connection: 4THE6

Cable colour Terminal Terminal Designation

AMP plug seal plug AMP plug
White 1A 1 ground
Brown 2A 2 ground 1 2 3 4 5 6 7
Green 3A 3 battery + A
Yellow 5A 4 battery + B
Grey 6A 5 fine control, axis 2 C
D
Pink 7A 6 axis 2, auxiliary output 1
Blue 1B 7 safety input
Red 2B 8 axis 2, auxiliary output 2 Seal plug DEUTSCH-HDB
Black 3B 9 axis 2, common main return current
Violet 4B 10 dead man input contact 31 20
White-brown 5B 11 axis 2, common main return current 30 8 21

White-green 6B 12 fault display output 18

19
2
9
10
White-yellow 7B 13 axis 1, main output 2 29 7 3 22

White-grey 1C 14 axis 1, common main return current 28

17
6
1
4
11
23
White-pink 2C 15 axis 1, main output1 16 5 12

White-blue 3C 16 axis 1, common main return current 27

15
14
13
24
Brown-green 6C 19 diagnosis output 26 25

Brown-grey 1D 21 axis 2, main output 2

Brown-pink 2D 22 axis 2, main output 1
Brown-blue 3D 23 axis 1, auxiliary output 1 * Type 2.2 contains an automatic locking
Brown-red 4D 24 axis 1, auxiliary output 2 of the parametering. This locking starts
White-black 5D 25 fine control, axis1 when switching of the PCTHE6/PROG
White-red 6D 26 parameter key* console tools.

Terminal connection: 6THE6

Cable colour Terminal Terminal Designation
AMP plug seal plug AMP plug
White 1A 1 ground 1 2 3 4 5 6 7
Brown 2A 2 ground A
Green 3A 3 battery + B
Yellow 5A 4 battery + C
Grey 6A 5 fine control, axes 1, 2, 3 D
Pink 7A 6 axis 2, auxiliary output 1
Blue 1B 7 safety input
Red 2B 8 axis 2, auxiliary output 2
Black 3B 9 axis 2, common main return current
Violet 4B 10 dead man input contact Seal plug DEUTSCH-HDB
White-brown 5B 11 axis 2, common main return current
White-green 6B 12 fault display output
20
White-yellow 7B 13 axis 1, main output 2 30
31
8 21
White-grey 1C 14 axis 1, common main return current 19 9

White-pink 2C 15 axis 1, main output 1 29

18
7
2
3
10
22
White-blue 3C 16 axis 1, common main return current 17 1 11
23
28 6 4
White-red 4C 17 axis 3, main output 1 16 5 12
White-black 5C 18 axis 3, main output 2 15 13
27 24
Brown-green 6C 19 diagnosis output 26
14
25
Brown-yellow 7C 20 axis 3, common main return current
Brown-grey 1D 21 axis 2, main output 2
Brown-pink 2D 22 axis 2, main output 1 * Type 2.2 contains an automatic
Brown-blue 3D 23 axis 1, auxiliary output 1 locking of the parametering. This
Brown-red 4D 24 axis 1, auxiliary output 2 locking starts when switching off the
Brown-black 6D 26 parameter key* PCTHE6/PROG console tools.
Green-pink 3A 27 battery +
Green-grey 1A 28 ground

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Unit dimensions: 2THE 6 (Dimensions in mm)

25° 25°

Ø 18

199
13,5

28
39

62

173,2
145
143,7
174
1-1 1-2
125,5

93 38,5
110
Ø 8,5
31

116,5 Cable length : 1m

136
136,5

Unit dimensions: 2THE 6 R (Dimensions in mm)

12° 12°
94
151 130 70,2
61,5

M12
49
25

24
45,8

93
39

1-1 1-2
172,3
173

110
38,5
4 x Ø9
72
40

160
Cable length: 1m
180

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 RE 29 771/09.97

Unit dimensions: 4THE 6 (Dimensions in mm)

Grip curved by 15 °
towards the control
port 2-2

ø108

2 1

20°20' 2 8°2 0 0' 2 0° 2 0

' 28°2 '
15°
110

wire length: 300

415
25,5

ø71

2-1 1-1 2-1 1-1

167

2-2 1-2
25

93
ø
108 108

Cable length: 1m
63
ø7
ø108
56

100x100
3
ø9

3 R7

Front of grip
lies towards control
port 1-1

1 Lever deflection when actuating 2 2 Lever deflection when actuating one 3 Fixing holes
actuators simultaneously actuator

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Ordering details

THE 6 2X *
One axis unit = 2
Two axes unit = 4
Three axes unit = 6

Electric outputs Further

Additional outputs = A details in
Without additional outputs = S clear text

Actuating element
Ergonomic grip (only 4THE 6) = AE
Grip for three axes unit (only 6 THE 6) = BT
Lever with plastic end piece (only 2 THE 6) = LT
Lever with detent in 3 switched positions = LM
Lever with friction coupling = LF
Curve pedal = RC
Flat pedal = RP

Series 20 to 29 =2X
(20 to 29 : unchanged installation and connection dimensions)

Neutral switch, independent of the electronic acquisition

With neutral switch (only 2 THE 6) = N
Without neutral switch = S

Connection flange
Square flange for 4 THE 6 and 6 THE 6 = Q
Rectangular flange for 2 THE 6 and 2 THE 6 R = R

Main plug
Plug AMP MIC 27 = 10
Sealed plug IP 67 = 20

Type details for ergonomic grip

Arrangement of E-contacts at
ergonomic grip (see page 4) = TT, ST, VT, YT, YU

Grip orientation
Lever straight and grip in the direction of control port 1-2 = 03
Lever curved by 15° in the direction of control port 2-2
and grip in the direction of control port 1-2
(pilot oil unit for the left hand) = 43

Lever curved by 15° in the direction of control port 2-1

and grip in the direction of control port 1-2
(pilot oil unit for the right hand) = 23
Plug (only 4 THE 6)
DEUTSCH seal plug IP 67 = 5
for wiring of the grip (see page 11)
Plug AMP MAT-N-LOK = 6
for wiring of the grip (see page 11)
Without plug = No code

Suitable consoles : Note: For special types

– Programming and diagnosis console PROG – grip with three axes,
for THE 6 - 2X – special parametering,
– Diagnosis console DIAG for THE 6 - 2X – other solenoid types ...
PCTHE6 interface please consult Mannesmann Rexroth S.A. (see page 12 for
address).

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Location of the contacts within the plugs for wiring the grips

DEUTSCH sealed plug IP 67 Plug AMP MAT-N-LOCK

(ordering detail = 5) (ordering detail = 6)

Grip ST Grip ST
F
F

2 1
2
1

View F View F

Grip VT or YT Grip VT or YT

F
F

1 6 1 2 3
2 5 4 5 6
3 4

View F
View F

Identification Ergonomic grip Identification Ergonomic grip

Wire Wire
in the version in the version
colour colour
plug VT YT plug VT YT
1 red x x 1 grey x x
2 black x x 2 black x x
3 grey x x 3 red x x
4 blue x x 4 blue x x
5 yellow x 5 yellow x
6 green x 6 green x

Grip YU Grip YU
F
F

1 2 3
1

4 5 6
2

7
3

7 8 9
4

View F
View F

Identification Identification Wire Identification Identification Wire

Wire Wire
in the in the colour in the in the colour
colour colour
plug plug plug plug
1 red 5 yellow 1 grey 5 yellow
2 black 6 gren 2 black 6 green
3 grey 7 white 3 red 7 white
4 blue 8 brown 4 blue 8 brown

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Notes

Mannesmann Rexroth AG Mannesmann Rexroth S.A.

D-97813 Lohr am Main Division Sigma International
Jahnstraße 3–5 • D-97816 Lohr am Main BP 101 - 91, bd Irène Joliot-Curie
Telefon 0 93 52 / 18-0 • Telefax 0 93 52 / 18-10 40 F-69634 Vénissieux cédex
Telex 6 89 418 Tél. 04 78 78 52 52 - Fax. 04 78 78 52 26 - Télex 380 852

The specified data is for product description purposes only and may not be deemed to be
12/12 guaranteed unless expressly confirmed in the contract. All rights reserved – Subject to revision