Bosch R901234567 Operating Instructions Manual Download Page 1

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Operating instructions
RE29583-XL-B/09.20

Replaces: 01.18
Document no.: RA87650010_AA
English

Directional servo valve with

mechanical position feedback

(Area of application according to the Explosion Protection
Directive 2014/34/EU:

II 3G

)

Type 4WS2EM 10...XL...

Summary of Contents for R901234567

Page 1: ...ing instructions RE29583 XL B 09 20 Replaces 01 18 Document no RA87650010_AA English Directional servo valve with mechanical position feedback Area of application according to the Explosion Protection Directive 2014 34 EU II 3G Type 4WS2EM 10 XL TM R ...

Page 2: ...αι αυτές οι προϋποθέσεις απευθυνθείτε στους κατά τόπους αντιπροσώπους της Bosch Rexroth ή σε κάποιο εξουσιοδοτημένο σέρβις Για τα σχετικά στοιχεία επισκεφτείτε την ιστοσελίδα www boschrexroth com ES La puesta en marcha de este producto únicamente podrá realizarse cuando disponga de las instrucciones de servicio en una lengua oficial de la UE comprensible para usted y haya entendido su contenido En...

Page 3: ...ompreendido seu conteúdo Se não for esse o caso entre em contato com a pessoa de contato da Bosch Rexroth ou com o centro de serviço responsável Você também pode encontrá las em www boschrexroth com RO Aveţi voie să puneţi în funcţiune acest produs doar dacă aveţi acest manual de utilizare într o limbă oficială a UE pe care o înţelegeţi şi după ce aţi înţeles conţinutul Dacă aceste condiţii nu sun...

Page 4: ...he user from the obligation of own judgment and verification Our products are subject to a natural process of wear and aging All rights with Bosch Rexroth AG also in case of applications for industrial property protection It may not be reproduced or given to third parties without consent of Bosch Rexroth AG The cover shows an example configuration The product supplied may therefore differ from the...

Page 5: ...t information 17 5 1 Product identification 18 6 Transport and storage 22 6 1 Valve transport 22 6 2 Storing the hydraulic valve 22 7 Installation 24 7 1 Unpacking 24 7 2 Changes to the surface protection of the valve 24 7 3 Installation conditions 24 7 4 Prior to assembly 25 7 5 Required tools 25 7 6 Required accessories 25 7 7 Assembling the valve 26 8 Commissioning 33 9 Operation 34 9 1 General...

Page 6: ... 10 XL RE29583 XL B 09 20 13 Extension and modification 41 14 Troubleshooting 42 14 1 How to proceed for troubleshooting 42 15 Technical data 43 16 Appendix 44 16 1 List of addresses 44 17 Declaration of conformity 45 18 Index 46 ...

Page 7: ...ns and chapter 3 General information on damage to property and damage to product before working with the product 1 2 Required and amending documentation The product may not be commissioned until you have been provided with the documentation marked with the book symbol and you have understood and observed it Table 1 Required and amending documentation Title Document number Document type Directional...

Page 8: ...e of danger Consequences Describes the consequences of non compliance Precaution Specifies how the danger can be prevented Table 2 Risk classes according to ANSI Z535 6 2006 Warning sign signal word Meaning DANGER Indicates a dangerous situation which will cause death or severe injury if not avoided WARNING Indicates a dangerous situation which may cause death or severe injury if not avoided CAUTI...

Page 9: ...equipment P Hydraulic connection pump RE Rexroth document in English language T Hydraulic connection tank X Y Hydraulic connections pilot oil 2 Safety instructions 2 1 General information on this chapter The product has been manufactured according to the generally accepted codes of practice However there is still the danger of personal injury and damage to property if you do not observe this chapt...

Page 10: ...on application or performance data than defined by Bosch Rexroth AG in these operating instructions please contact Bosch Rexroth AG beforehand The valve must not be used with other connection application and performance data than defined in these operating instructions without the written approval by Bosch Rexroth AG 2 3 Improper use Any use deviating from the intended use is improper and thus not...

Page 11: ...rt knowledge refers to the following Reading and completely understanding hydraulic schemes In particular completely understanding the correlations regarding the safety equipment and Having knowledge of the function and set up of hydraulic components Personnel shall be qualified as follows to the extent necessary to fulfill their tasks Understanding of the general principles of explosion protectio...

Page 12: ...azard to persons due to unsuitable spare parts Comply with the technical data and environmental conditions specified in the product documentation The installation or use of inappropriate products in safety relevant applications could result in unintended operating states when being used which in turn could cause personal injury and or damage to property Therefore only use a product for safety rele...

Page 13: ...utside the approved temperature ranges the explosion protection no longer applies Only use the valve within the intended environmental and hydraulic fluid temperature range Pressurized system parts and leaking hydraulic fluid When working on hydraulic systems with stored pressure energy accumulators or cylinders working under gravity the valve may even be pressurized after the pressure supply has ...

Page 14: ...the valve In the worst case this may result in unexpected system movements and thus constitute a risk of injury for persons Ensure an adequate hydraulic fluid cleanliness according to the cleanliness classes of the valve over the entire operating range Leakage in case of incorrect working temperatures The use of the valve outside the approved temperature ranges may lead to permanent leakage at the...

Page 15: ... supplied valve complies with the required category and the corresponding zone The machine end user of the Bosch Rexroth valve is responsible that the valve is only being used according to the intended use as defined in these operating instructions the valve is only stored operated and maintained according to the technical data operating and environmental conditions indicated in Data sheet 29583 X...

Page 16: ...lve as handle or step Do not place put any objects on top of it Dirt and foreign particles in the valve Penetrating dirt and foreign particles in the valve lead to wear and malfunctions The safe function of the valve is therefore no longer ensured During installation ensure utmost cleanliness in order to prevent foreign particles such as welding beads or metal chips from getting into the hydraulic...

Page 17: ...e of delivery for completeness Check the scope of delivery for possible transport damage see chapter 6 Transport and storage In case of complaints please contact Bosch Rexroth AG see chapter 16 1 List of addresses Accessories such as valve subplates are not included in the scope of delivery and must be ordered separately See chapter 7 6 Required accessories 5 Product information For information on...

Page 18: ...year and week e g FD 03W01 7 Maximum operating pressure e g pmax 315 bar 8 Ambient temperature range 30 C Ta 80 C 9 Hydraulic symbol according to ISO 1219 Graphic 10 Designation of origin Made in Germany 11 Name and address of the manufacturer Bosch Rexroth AG D 97816 LOHR 12 Customer s or production order number e g 123456789012345678 13 Customer material number or additional information e g CNR ...

Page 19: ...e atmospheres in which explosive gases mists or vapors device group II occur permanently or for a long time or frequently Corresponds to zone 0 according to Directive 1999 92 EC Very high safety level 0 1 2 II 2G Potentially explosive atmospheres in which explosive gases mists or vapors device group II are occasionally present Corresponds to zone 1 according to Directive 1999 92 EC High safety lev...

Page 20: ...te that in areas which are potentially explosive due to explosive gases mists or vapors zone 0 1 2 for which device group II categories 1G 2G and 3G are intended the maximum surface temperature of the valve must in addition be below the ignition temperature of the surrounding explosive gas mist or vapor Based on their maximum surface temperature these hydraulic products are classified according to...

Page 21: ...pes of protection Type of protection Meaning Relevant for non electrical devices Electricaloperating equipment b Ignition source monitoring X c Structural safety X d Flameproof enclosure X X e Increased safety X fr Flow restricting enclosure X g Intrinsic safety X k Liquid immersion X o Oil immersion X p Pressurized enclosure X X q Powder filling X m Encapsulation X i Intrinsic safety X Type of pr...

Page 22: ...addresses Report any transport damage to your responsible sales contact person within one week The addresses of the sales subsidiaries can be found on the Internet on http www boschrexroth com adressen 6 2 Storing the hydraulic valve Hydraulic valves are delivered in an unobjectionable state For the transportation and storage of the product always observe the environmental conditions specified in ...

Page 23: ...case of questions regarding spare parts please contact the Rexroth service responsible for your valve see chapter 10 7 Spare parts If a dismounted valve is to be stored it has to be preserved for protection against corrosion for the duration of storage Rexroth recommends the following procedure 1 Clean the valve see chapter 10 1 Cleaning and care 2 Close all connections so that they are airtight 3...

Page 24: ...l bearing ground Only open the packaging from the top Dispose of the packaging in accordance with the national regulations of your country 7 2 Changes to the surface protection of the valve WARNING Explosion hazard due to modifications to the valve Any change in the surface protection of the valve will lead to a loss of the explosion protection The valve must not be painted or otherwise coated wit...

Page 25: ...instructions 7 5 Required tools You only require standard tools to assemble the valve 7 6 Required accessories The following accessories are recommended for the connection of the valve These accessories can be ordered separately from Bosch Rexroth Subplates with dimensions for valves with porting pattern according to ISO 4401 are listed in the Data sheet 45100 Table 10 Flushing plate Material numb...

Page 26: ...ng plate using mounting screws of reduced stability may cause the flushing plate to become loose Consequently hydraulic fluid may leak and lead to personal injury and or damage to property Completely assemble the flushing plate according to the assembly specifications using suitable assembly aids Observe the tightening torques screw stabilities and the minimum length of the mounting screws Always ...

Page 27: ...screws with a tightening torque of 12 5 Nm 1 5 Nm with a friction coefficient of µtotal 0 09 0 14 This tightening torque refers to the maximum admissible operating pressure The use of a directional valve with port in accordance with ISO 4401 05 05 0 05 is suited better than a flushing plate This valve can also be used for flushing the actuator ports The following is a guideline for the necessary f...

Page 28: ...ular caution applies to valves with suspended installation Completely assemble the valve according to the assembly specifications by means of suitable assembly aids Only assemble the valve at blocks or plates suitable for the weight of the valve Observe the tightening torques screw stability and the minimum length of the valve mounting screws CAUTION Insufficient installation space Insufficient in...

Page 29: ...from the valve and keep it safe for returns in case any repairs become necessary later 3 Dry the valve connection surface using suitable cleaning materials 4 Check the seal rings at the valve connection surface for completeness Other sealants are not admissible 5 Remove existing preservative agent 6 Check whether at the subplate the pressure connecting line is connected to P and the return line to...

Page 30: ...of the valve and the complete machine or system Assemble lines and hoses without stress 1 Depressurize the relevant system part 2 Establish all connections observing the operating instructions of the system 3 Make sure that pipes and or hoses are connected to all ports and or that the ports are closed with plug screws 4 Carry out a special check to make sure that the cap nuts and flanges are corre...

Page 31: ...e subplate on which the valve is fitted must be electrically conductive and included in the equipotential bonding according to EN 60079 14 and IEC 60364 4 41 CAUTION Danger of damage to property and personal injury Faulty energy supply may lead to uncontrolled valve movements These could result in possible malfunctions or failure of the valve and cause injury Always observe country specific regula...

Page 32: ...buckets Observe the specified pin assignment see Data sheet 29583 XL 3 When all braided wires are soldered in visually inspect the plug in connector on the contact side 4 Completely assemble the mating connector according to the assembly instructions The torques depend on the line 5 When routing the control line make sure it is strain relieved 6 Fit the mating connector on the connector and screw ...

Page 33: ...raulic system ensure that the maximum admissible pressure of the hydraulic valve in the system is not exceeded by any means Ensure that in your system the maximum admissible operating pressure is secured by means of a pressure limitation element Damage to persons and property The commissioning of the valve requires basic hydraulic and electrical knowledge Only qualified personnel see section 2 4 Q...

Page 34: ...onance or fluid noises such as whistling In continuous operation these noises may cause hearing damage in persons or damage to the valves In this case contact a service engineer Only use the valve within the performance range provided in Data sheet 29583 XL The machine and or system manufacturer is responsible for the correct project planning of the hydraulic system and its control Changing the se...

Page 35: ... valve cap and damage the valve Do not use high pressure washers for cleaning For cleaning and care of the valve please observe the following Close all openings with appropriate protective caps devices Ensure that all seals and electrical connections are firmly attached so that no humidity can penetrate the valve during cleaning Remove external coarse dirt and keep sensitive and important parts cl...

Page 36: ...s for completeness and tight seat 4 Check the mating connector connector and connection line for damage and tight seat 5 Check the valve for external leakage and replace the sealing devices if required see chapter 10 6 Rectifying external leakages 10 3 Maintenance schedule Valves are low maintenance provided that they are used as intended To ensure that the valve functions reliably for a long time...

Page 37: ...nnector will lead to loss of the explosion protection 10 5 Exchanging the filter element The valve contains an installed exchangeable filter element You can also exchange the filter element if the valve has already been installed Replacement filter elements with FKM seal are available as spare part see 10 7 Spare parts In case of contamination you must exchange the filter element as follows Fig 3 ...

Page 38: ...onnection surface 1 Remove the valve see chapter 11 Disassembly and removal 2 Inspect the contact surfaces for seal rings at the valve for cleanliness and damage 3 Inspect the seal rings and recesses on the connection flanges for cleanliness and damage 4 Dry the mounting surface and the contact surface using suitable cleaning materials 5 Assemble the new seals 6 Assemble the valve at the contact s...

Page 39: ...ized system parts there is the danger of injury by leaking hydraulic fluid or electric current Before disassembly ensure that the hydraulic system is depressurized and the electrical control is de energized Explosion hazard and or risk of fire due to the ignition of an existing explosive atmosphere Serious injury caused by explosion pressure and fire may result During disassembly and exchange work...

Page 40: ... valve is exchanged all further steps are analogous to mounting see chapter 7 Assembly 12 Disposal 12 1 Environmental protection A careless disposal of the valve and the hydraulic fluid could lead to environmental pollution Thus dispose of the product and the hydraulic fluid in accordance with the currently applicable national regulations in your country Dispose of hydraulic fluid residues accordi...

Page 41: ...e effects on human beings and on the environment have to be expected The hydraulic valves basically consist of Cast iron Steel Aluminum Copper Plastics Electronics components and assemblies Elastomers 12 5 Recycling Due to the high metal content hydraulic products can mostly be recycled In order to achieve an ideal metal recovery their disassembly into individual assemblies is required The metals ...

Page 42: ...whether the valve was functioning properly in conjunction with the overall system before the error occurred Try to determine any changes to the overall system in which the valve is integrated Have there been any changes to the application conditions or to the area of application of the valve Have any changes e g refittings been made or has any repair work been carried out on the overall system mac...

Page 43: ...rn Remove valve and have it repaired Bad dynamic behavior Filter contaminated Exchange filter element and check system for contamination Orifice contaminated Remove valve and have it repaired Instable zero point Control spool friction due to contamination Remove valve and have it repaired Hysteresis Control spool friction due to contamination Remove valve and have it repaired Large zero point devi...

Page 44: ...in Germany Phone 49 0 9352 40 50 60 Email service boschrexroth de Headquarters Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Phone 49 0 9352 40 30 20 Email my support boschrexroth de The addresses of our sales and service network and sales organizations can be found at www boschrexroth com adressen Contacts for transport damage repair and spare parts Ordering address for accessorie...

Page 45: ...Declaration of conformity 45 48 RE29583 XL B 09 20 4WS2EM 10 XL Bosch Rexroth AG 17 Declaration of conformity ...

Page 46: ...List of addresses 44 M Maintenance 35 Maintenance schedule 36 Materials used 41 Mating connector 26 Modification 41 N Name plate 18 O Obligations of the machine end user 15 Operation 34 P Packaging 41 Personal protective equipment 15 Q Qualification of personnel 11 R Recycling 41 Repair 35 37 Required and amending documentation 7 Required tools 25 S Safety instructions 9 12 13 Scope of delivery 17...

Page 47: ...Index 47 48 RE29583 XL B 09 20 4WS2EM 10 XL Bosch Rexroth AG ...

Page 48: ...osch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Tel 49 0 9352 40 30 20 my support boschrexroth de www boschrexroth com Subject to change without notice Printed in Germany RE29583 XL B 09 20 ...

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