Rexroth (Aventics) 0820055102 Pneumatisches Magnetventil

Bosch Rexroth’s pneumatics division has been rebranded as AVENTICS, while the original part numbers remain unchanged.

Full Model Alias: HF03-3/2CC-024Gleichstrom

Ventilfunktion: Dual 3/2-way solenoid valve (2×3/2, Normalerweise geschlossen + Normalerweise geschlossen)

1. Wichtige Spezifikationen

2. Interpretation des Modellcodes

Serie 0820 = HF03-LG modular valve manifold solenoid valve

0820055xxx: HF03 series compact electrically operated directional valve

102: Function code → 2×3/2 CC (two independent 3/2-way, normalerweise geschlossen)

Electrical definition: Dual coils, independently control two separate 3/2 pneumatic circuits.

3. Pneumatic Function Description

Two independent 3/2-way valves:

De-energized (coil off): Hafen 1 Zu 2 blocked; Hafen 2 connected to exhaust port 3

Energized (coil on): Hafen 1 connected to port 2; Hafen 3 blocked

Typische Anwendungen: Vacuum control, dual single-acting cylinder control, widely fitted on Homag woodworking machinery.

4. Kompatibilität & Matching Information
5. Coils: Coils are integrated into valve body, supplied as one assembly. Cannot be interchanged with coils of other HF03 5/2-way valves.
6. Base Plate: Compatible with HF03 series integrated valve manifold subplates.
7. Elektrische Schnittstelle: Multi-pin bus / collective wiring for valve manifolds; no separate cable outlet.
8. Reference for Similar Models

0820055052: 5/2-way single-solenoid valve

0820055102: 2×3/2 dual 3/2-way valve (dieses Modell)

5. Auswahl & Richtlinien zur Fehlerbehebung
6. External pilot pressure ≥2.5 bar is mandatory. Insufficient supply pressure causes failure to switch.
7. Medium temperature must not drop below 0 ℃ to prevent condensate ice from jamming the spool.
8. Positive overlapping spool design → not suitable for high-frequency micro-flow vacuum holding applications.
9. Do NOT directly replace with a 5/2-way valve; pneumatic function circuits differ completely.
10. Install a 5 μm precision filter upstream; dust contaminants easily cause spool sticking.
11. Typische Anwendungen

Woodworking CNC machining centers (Homag), automated assembly lines, vacuum handling systems, Verpackungsmaschinen, compact valve manifold pneumatic control.

If required, I can provide:

✅ Simplified pneumatic circuit symbols

✅ Excerpts from official datasheet

✅ List of functionally equivalent replacement models

✅ Inquiry for matching valve manifold base plate part numbers

Operating Principle of Aventics (Rexroth) 0820055102

Vollständige Modellbezeichnung: 0820 055 102 HF03, 2×3/2 CC Dual 3/2-Way Solenoid Valve

Basic Construction: Pilot-operated spool valve, soft sealing, two independent solenoid coils, two isolated 3/2 pneumatic circuits, externally piloted air supply

1. Structural Breakdown
2. Main Spool Assembly: Two independent built-in spools (Channel A / Channel B)
3. Two independent solenoid pilot units (Spule 1 / Spule 2, 24 VDC)
4. Common main supply port (Hafen 1, shared for working air and pilot air)
5. Pneumatic port allocation:

Kanal 1: 1 (Liefern), 2 (Load Output), 3 (Auspuff)

Kanal 2: Separate independent set of ports 1, 2, 3

CC abbreviation: Normalerweise geschlossen (default closed position)

2. Core Operating Principle (Externally Piloted Spool Valve)

⚠️ Critical prerequisite: Minimum external pilot pressure ≥2.5 bar for reliable valve switching

The built-in solenoid only controls a miniature pilot air circuit. The coil does not drive the main spool directly; compressed air pressure actuates the main spool.

State 1: Both coils de-energized (default resting position)

Return springs hold both spools at home position.

Pneumatic status (identical for both circuits):

✅ Supply port 1 ➜ Blocked, air supply to load port 2 cut off

✅ Load port 2 ➜ Connected to exhaust port 3

👉 Load pressure relieved; applicable for single-acting spring return cylinder retraction, vacuum generator shutdown, vacuum cup air blow-off.

State 2: 【Coil 1 Energized, Spule 2 De-Energized】

Spule 1 energizes, opens the micro pilot air passage;

Pilot air pressure pushes the first main spool to switch position.

Pneumatic switching for Circuit 1:

✅ Supply port 1 ➜ Connected to load port 2

✅ Exhaust port 3 ➜ Blocked

👉 Air supply pressurizes the load;

Schaltung 2 remains unchanged and stays exhausted.

State 3: 【Coil 2 Energized, Spule 1 De-Energized】

Only the second spool switches; Schaltung 2 receives air supply, Schaltung 1 remains exhausted.

⚠️ Important: Two coils operate independently without mechanical linkage. One circuit can supply air while the other exhausts for fully separated dual control.

❌ Avoid continuous simultaneous energization of both coils. No hardware interlock; software interlock must be implemented in machine control program.

3. Pneumatic Function Diagram Description (2×3/2 NC)

For each individual circuit:

De-energized: 2 ↔ 3 (Auspuff), Hafen 1 blocked

Energized: 1 ↔ 2 (Liefern), Hafen 3 blocked

4. Pilot-operated vs Direct Acting (Root Cause of Spool Jamming)
5. Direct acting valve: Electromagnetic force drives spool directly with limited thrust.
6. This externally piloted valve: Solenoid only controls low-flow pilot air; supply air pressure drives the larger main spool.

Vorteile: Kompakte Abmessungen, high flow capacity (850 L/min), low coil power consumption (0.35 W).

Disadvantage: The valve cannot switch at all if supply pressure falls below 2.5 Bar, the most common on-site fault.

5. Luftstrom & Spool Sequence (Simplified for Single Circuit)

Compressed air supply → Common inlet Port 1

Coil de-energized: Spring pushes spool → Port 2 links to 3, load exhausts

Coil energized: Pilot pressure overcomes spring force and shifts spool → Port 1 links to 2, load pressurized

6. Typical Working Scenario (Homag Woodworking Machinery)

Two independent vacuum suction cups controlled separately:

Coil energized → Air supply to vacuum generator, suction cup generates vacuum for workpiece holding

Coil de-energized → Suction cup exhausts, vacuum released and workpiece unloaded

7. Fault Correlation for On-Site Troubleshooting
8. Supply pressure <2.5 bar → Insufficient pilot thrust, spool cannot shift, valve fails to switch despite powered coil
9. Wasser & contaminants in compressed air → Scaling on spool sliding surfaces, spool seizure
10. Long-term operation with dry, non-lubricated air → Degraded lubrication, slow switching response
11. Single coil burnout → Corresponding circuit fails to switch, the second circuit continues normal operation

I can provide upon request:

1. Text-based pneumatic flow schematic
2. Electrical control wiring logic explanation
3. Performance comparison with other 0820055 series 5/2-way valves

Critical Distinction (Common Misconception)

Many technicians mistake this for a double-solenoid 5/2-way valve.

0820055102 is NOT a 5/2 Ventil! It integrates two fully independent 3/2-way valves within one 16 mm valve slice. The two pneumatic circuits are completely isolated with no interconnection.

Complete Application Scenario Analysis of Rexroth/Aventics 0820055102 (HF03-LG 2×3/2CC 24VDC)

Pre-Review of Core Characteristics

Valve specifications: Integrated two independent normally closed 3/2-way valves (isolated pneumatic circuits), externally piloted, 16 mm width for valve manifold mounting, two separate 24 VDC coils.

Pneumatic function per circuit:

Coil de-energized: 2↔3 (Auspuff), Hafen 1 blocked; Coil energized: 1↔2 (Liefern), Hafen 3 blocked.

Kernvorteile: One valve slice delivers dual independent control, saving manifold installation space; geringe Leistung 0.35 W coil; flow rate up to 850 L/min; compatible with both positive pressure pneumatic circuits and negative vacuum circuits.

Einschränkungen: Requires minimum 2.5 bar pilot pressure for switching; positive overlapping spool not suitable for high-frequency, long-duration vacuum holding requiring zero leakage.

Largest installed base: Homag CNC woodworking machining centers, the most classic OEM application.

1. Holzbearbeitungsmaschinen (Primäre Anwendung)

Homag CENTATEQ CNC Machining Centers, Edgebanders, Sanders

Working Case 1: Zoned Vacuum Cup Control (Am häufigsten verwendet)

One valve controls two independent suction cup groups:

Spule 1 energized → Activate vacuum generator supply, vacuum builds up for panel holding

Spule 1 de-energized → Suction cup exhausts, vacuum broken, workpiece released

The second coil controls another set of suction cups separately. Enables selective activation of vacuum zones for different workpiece sizes, reduces vacuum energy consumption and prevents thin panel deformation.

✅ Benefit: Dual independent control saves manifold slot space compared to installing two separate 3/2-way valves.

Working Case 2: Single-acting Clamping Cylinders, Material Stops, Position Pins

Woodworking equipment extensively uses spring return single-acting cylinders:

Coil energized: Air supply extends cylinder (position pin pop-up, stop barrier raised)

Coil de-energized: Air exhausts, spring retracts cylinder

One valve controls two separate positioning cylinders.

Working Case 3: Blow-off for Dust Removal & Table Cleaning

One circuit controls vacuum suction cups, the second controls air blow nozzles. After machining completes, cups release workpieces and nozzles blow away wood chips.

2. Automated Packaging Machinery
3. Vacuum Pick & Place Systems

Two independent vacuum cups for alternating picking of cartons, boxes and plastic films; one suction circuit active, one standby.

2. Single-acting Clamps & Material Stops

Limit stops and side push positioning mechanisms (spring return cylinders) on packaging conveyor lines.

3. Bag Opening via Air Blowing

One circuit grips film by vacuum, the second supplies positive air pressure to open plastic bags.

⚠️ Selection Reminder: High-speed horizontal packaging machines requiring stable long-term vacuum holding are not recommended. Positive overlapping spool creates minor internal leakage leading to gradual vacuum decay.

3. Non-Standard Automation Assembly Lines, 3C & Electronics Equipment
4. Small spring ejectors and material hold-down mechanisms (single-acting cylinders)
5. Dual-station vacuum handling modules: Separate suction cups for alternating loading/unloading
6. Auxiliary pneumatic switching and purge circuits for airtight testing

Suitable for PCB transportation, plastic component assembly and small workpiece handling.

Environment requirement: Clean supply air; installieren 5 μm upstream filter for dusty production sites.

4. Logistiksortierung & Panel Handling Equipment
5. Zoned vacuum cup control at the end effector of panel, glass and carton handling robots
6. Pneumatic diverting barriers on sorting conveyors (single-acting cylinders)
7. Stoppers on transport lines.
8. Kunststoffspritzguss & Gummimaschinen
9. Mold air blow circuits for part ejection
10. Small vacuum cups for removing molded components
11. Single-acting ejector pin control.

Recommended Pneumatic Wiring Schemes

Scheme A: Dual Independent Vacuum Generator Control (Homag Standard Wiring)

Common Port 1: Compressed air supply

Output Port 2: Air supply inlet of vacuum generator

Exhaust Port 3: Equipped with silencer

Coil energized → Vacuum generator operates, suction cup holds workpiece; Coil de-energized → Vacuum stops, workpiece released naturally.

Scheme B: Control of Two Single-Acting Spring Return Cylinders

Common Port 1: Luftzufuhr

Output Port 2: Cylinder inlet

Hafen 3: Auspuff

Cylinder extends when coil energized; retracts by spring when de-energized.

Scheme C: One Circuit for Vacuum Suction + One Circuit for Blow-off (Advanced Configuration)

Kanal 1: Control vacuum generator (workpiece holding)

Kanal 2: Independent positive-pressure blow circuit (fast vacuum break to avoid workpiece adhesion)

Prohibited Applications | Selection Pitfalls

1. Cannot directly drive double-acting cylinders

Double-acting cylinders require 5/2-way valves. A 2×3/2 valve cannot achieve reciprocating cylinder motion – a frequent engineering mistake.

2. Long-duration high-vacuum sealed chamber holding

Positive overlapping spool has minor internal leakage; vacuum pressure decays gradually over time, unsuitable for sealed vacuum chamber long-term pressure retention.

3. Continuous supply pressure below 2.5 Bar

External pilot design results in insufficient thrust to shift spools; valve receives power but fails to actuate.

4. Umgebungstemperatur <0 ℃, high humidity with heavy condensate

Ice formation from condensed water causes spool sticking; a refrigerated dryer for compressed air is mandatory.

5. Strong corrosive acidic gas environments

Standard NBR rubber seals are incompatible with corrosive media.

Why OEM Machine Builders Prefer 0820055102 Over Two Separate 3/2-Way Valves?

1. Save manifold installation space: One 16 mm slice delivers dual control, shortening valve manifold length and reducing control cabinet size.
2. Unified common air supply passage simplifies manifold internal air routing.
3. Standardized base plate design simplifies centralized wiring.
4. Modular HF03 valve manifold compatible with fieldbus systems (multi-pin connector, Profibus etc.), suitable for high-end Homag CNC equipment.

Functional Replacement Reference (Spare Part Exchange)

Direct replacement prerequisite: HF03-LG series valve manifold base plate

Original part number: 0820055102 (unique standard model)

NOT directly interchangeable: Andere 0820055 series 5/2-way valves (z.B. 0820055052) due to different pneumatic functions.

I can supply upon request:

1. Standard pneumatic circuit drawing for vacuum cup Homag configuration
2. Timing sequence control logic for Homag CNC
3. Troubleshooting checklist for common faults under different working conditions