Bosch REXROTH 4WRZ 7X/XE Series Operating Instructions Manual Download Page 1

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Operating instructions
RE29115-XE-B/09.19

Replaces: 04.16
Document no. RA78494073_AA
English

Proportional directional valves,

pilot-operated,

without electric position feedback

(area of application according to the explosion protection directive 2014/34/EU:

II 2G

)

Type 4WRZ..7X/...XE...

(IECEx certificate of conformity

of the valve solenoid)

Summary of Contents for REXROTH 4WRZ 7X/XE Series

Page 1: ...nt no RA78494073_AA English Proportional directional valves pilot operated without electric position feedback area of application according to the explosion protection directive 2014 34 EU II 2G Type 4WRZ 7X XE IECEx certificate of conformity of the valve solenoid ...

Page 2: ...ι 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: ...mpreendido 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 sunt...

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: ... Scope of delivery 17 5 Product information 17 5 1 Product identification 18 6 Transport and storage 22 6 1 Transporting the valve 22 6 2 Storing the hydraulic valve 22 7 Assembly 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 Commission...

Page 6: ...115 XE B 09 19 13 Extension and modification 43 14 Troubleshooting and fault correction 43 14 1 How to proceed for troubleshooting 43 15 Technical data 44 16 Appendix 45 16 1 List of addresses 45 17 Declaration of conformity 46 18 Index 47 ...

Page 7: ...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 Proportional directional valve pilot operated without electrical position feedback 29115 XE Data sheet General product information on hydraulic products 07008 Data sheet Subplates 45100 Data sheet Declaration of conformi...

Page 8: ...TION Indicates a dangerous situation which may cause minor or medium personal injury if not avoided NOTICE Damage to property The product or the environment could be damaged 1 3 2 Symbols The following symbols indicate notices which are not safety relevant but increase the comprehensibility of the documentation Table 3 Meaning of the symbols Symbol Meaning If this information is not observed the p...

Page 9: ...ic component You may use the product as follows as a proportional directional valve pilot operated without electrical position feedback for the intended use in an explosive atmosphere The product is only intended for professional use and not for private use Intended use includes having read and understood this documentation completely especially chapter 2 Safety instructions The valve is designed ...

Page 10: ...ded operating states when being used which in turn could cause personal injuries and or damage to property Therefore please only use a product for safety relevant applications if this use is expressly specified and permitted in the documentation of the product For example in explosion protected areas or in safety related control components functional safety Improper use of the product includes Fau...

Page 11: ...dge refers to the following Reading and completely understanding hydraulic schemes In particular completely understanding the correlations regarding the safety equipment and 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 protection protection cla...

Page 12: ... hazard 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 injuries and or damage to property Therefore only use a product for safety ...

Page 13: ...environmental and hydraulic fluid temperature range Valve solenoid has hot surface Risk of burning Provide a suitable touch guard During operation only touch the valve solenoid with heat protective gloves Allow the valve solenoid to cool down to room temperature before touching it directly with your hands during maintenance works Pressurized system parts and leaking hydraulic fluid When working at...

Page 14: ...in case of incorrect working temperatures Use of the valve outside the approved temperature range may lead to permanent leakage at the valves Thus hydraulic fluid in the form of a leaking hydraulic fluid jet may injure persons lead to damage to property and endanger the environment Only use the valve within the intended environmental and hydraulic fluid temperature range In case of leakage immedia...

Page 15: ...ve to be taken to avoid connected electric circuits being influenced by the remaining residual voltage peak if required In order to control the valve an analog direct current signal or a pulse width modulated PWM signal with 160 500 Hz and a maximum pulse voltage of 28 V is required 2 8 Personal protective equipment The machine end user must provide the personal protective equipment such as gloves...

Page 16: ...gn particles in the valve Penetrating dirt and foreign particles in the valve lead to wear and malfunctions The safe function of the valve can no longer be ensured During installation ensure utmost cleanliness in order to prevent foreign particles such as welding beads or metal chips from getting into the hydraulic lines Before commissioning ensure that all hydraulic connections are tight and that...

Page 17: ...e scope 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 and valve mounting screws are not included in the scope of delivery and must be ordered separately See chapter 7 6 Required accessories 5 Produc...

Page 18: ...plate is described in the correspondingly numbered fields of the following table Fig 1 Name plate for valves of size 10 Fig 2 Name plate for valves of size 16 25 32 Table 5 Information on the name plate of the main valve No Type of information 1 Manufacturer s logo 2 Material no of the valve 3 Type designation complete valve 4 Serial number of the valve 5 Manufacturer s factory number 6 Date of ma...

Page 19: ...rding to ISO 1219 10 Designation of origin 11 Name and address of the manufacturer 12 Production order number 13 14 CE mark 15 Explosion protection mark 16 Mark according to ATEX directive 2014 34 EU 17 Mark for the type of protection of the mechanical part according to EN 80079 36 18 19 135 95 230 Bosch Rexroth QR code ...

Page 20: ...cle according to IEC 34 1 VDE 0580 and frequency 8 Admissible ambient temperature range of the valve solenoid1 9 Explosion protection mark 10 Type examination certificate number 11 Mark for protection class according to ATEX directive 2014 34 EU 12 Mark for the type of protection according to EN 60079 7 or EN 60079 18 13 CE mark and identification of notified body 14 IECEx Certificate of Conformit...

Page 21: ...safety level II 1G Potentially explosive 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 areas where explosive gases mists or vapors device group II are occasionally present Corresponds to zone 1 according to direct...

Page 22: ...ty and transport Do not transport the valve using components with low stability e g solenoids connectors or cables Sharp edges Danger of cut injuries Wear suitable protective equipment for the transport of the safety valve Further information regarding transport is available from Bosch Rexroth see chapter 16 1 List of addresses Notify your responsible sales contact person any transport damage with...

Page 23: ... be closed properly again for storage Use the original packaging for storage 1 Check the complete valve for damages and corrosion prior to installation 2 In a test run check the valve for correct function and leak tightness After expiry of the maximum storage time we recommend having the valve checked by your competent Bosch Rexroth service In case of questions regarding spare parts please contact...

Page 24: ...ational regulations of your country 7 2 Changes to the surface protection of the valve WARNING Explosion hazard due to modifications to the valve In the event of changes to the surface protection of the valve the following points must be observed The valve solenoid must not be painted or otherwise coated with non conductive substances This leads to a loss of the explosion protection The valve hous...

Page 25: ...ty instructions in chapter 2 6 Product specific safety instructions Transport protection elements e g cover plates protective plugs must be removed prior to use in an explosive atmosphere 7 5 Required tools In order to assemble the valve you need standard tools only 7 6 Required accessories The following accessories are recommended for the connection of the valve These accessories are not included...

Page 26: ...o property Particular 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 spac...

Page 27: ...surface using suitable cleaning materials 5 Check the seal rings at the valve connection surface for completeness Other sealants are not admissible 6 Place the valve on the contact surface Only use valve mounting screws with the thread diameters screw lengths and strength properties listed in Data sheet 29115 XE Always fasten the valve with all valve mounting screws for the number of valve mountin...

Page 28: ...nd 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 correctly tightened...

Page 29: ...ide for proper equipotential bonding The base plate or 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 Explosion hazard caused by overheating An incorrectly dimensioned fuse protection may lead to overheating and thus cause an explosion A fuse which corresponds to the rated current according...

Page 30: ...ction and installation observe the requirements of EN 60079 14 Ensure that there are no bends in the connection line and braided wires to avoid short circuits and interruptions Only assemble the cable and line entries according to the assembly instructions Before assembly check whether the individual components of the cable and line entry are complete and that the sealing elements are undamaged Th...

Page 31: ... line entry is already screwed in the terminal box of the valve 1 De energize and depressurize the relevant system part 2 Open the terminal box internal hexagon wrench size 3 3 Remove the outer sheath of the connection line and the insulation of the individual conductors Press the wire end ferrules to the individual conductors For the stripping lengths refer to Fig 5 and Table 9 Fig 5 Stripping le...

Page 32: ...the double nipple 2 in the terminal box The outer sheath of the connection line must lie in the sealing insert 3 Otherwise explosion protection and the IP protection are no longer ensured 7 Screw the screw in bushing 4 to the double nipple 2 and tighten it securely hexagon nut wrench size 22 When tightening the screw in bushing 4 the solenoid coil must be supported in an appropriate manner or held...

Page 33: ...ning the valve solenoid make sure that it does not project over the valve connection surface After the rotation of the solenoid coil the coil pin must engage in the bore of the valve housing Make sure that the valve solenoid moves freely and does under no circumstance rest on the base plate A gap between valve housing and valve solenoid is not admissible Solenoid coils can be assembled in staggere...

Page 34: ...applications with different area ratios the hydraulic pressure is fortified and may in case of incorrect design lead to exceedance of the maximum admissible operating pressure Thus valves may burst or the cap elements may be ejected and cause personal injury Before commissioning the hydraulic system ensure that the maximum admissible pressure of the valve in the system is not exceeded by any means...

Page 35: ... every time the terminal box is opened and replace them if required Observe the operating instructions of the device and or system into which the valve is installed Before the actual operation switch the valve several times with reduced pressure 50 operating pressure This will press out any remaining air from the valve Thus mechanical damage caused by inadmissibly high acceleration of the fluid an...

Page 36: ...d See Data sheet 29115 XE CAUTION Loud noise An unfavorable arrangement of valves results in resonance or fluid noises such as whistling In continuous operation these noises may cause hearing damage in persons or damage at the valves In this case contact a service engineer Only use the valve within the performance range provided in Data sheet 29115 XE The machine and or system manufacturer is resp...

Page 37: ... with appropriate protective caps devices Check that all seals and caps of the plug in connections are firmly fitted so that no humidity can penetrate the valve during cleaning Remove external dirt and keep sensitive and important parts like valve solenoids clean Remove dust and dirt accumulations on the valve at regular intervals 10 2 Inspection and maintenance WARNING Uncontrolled machine moveme...

Page 38: ...ection line for tight seat 5 Check the valve for external leakage and replace the sealing devices if required see chapter 10 5 Rectifying external leakages 6 Open the terminal box and replace any damaged seals 7 Check the inside of the terminal box for corrosion Corrosion is an indication of leakage In case of visible corrosion remove the valve and have it repaired 8 Check the potting compound and...

Page 39: ...ting elements are to be checked with the system being switched off depressurized and cooled down 10 4 Repair WARNING Explosion hazard caused by improper repair Improper repair will void the explosion protection For repair works the valve may only be disassembled to the extent described in these operating instructions Defective parts may only be replaced by new interchangeable components in origina...

Page 40: ... kit terminal box Spare part Material number Seal kit terminal box contains 1 complete cable and line entry 1 blind plug with O ring 4 M4 hexagon socket head cap screws for the terminal box 4 x spring washers for the terminal box 1 x flat seal R961009879 For a valve with two valve solenoids two seal kits are required In case of questions about spare parts please contact your responsible Bosch Rexr...

Page 41: ...dium binding materials ready in order to collect or bind leaking hydraulic fluid 1 De energize and depressurize the relevant system part 2 Disconnect the electrical connections professionally 3 Prepare a container for collecting leaking hydraulic fluid 4 Use suitable tools to loosen the valve mounting screws of the valve 5 Remove the valve mounting screws and remove the valve from the connection s...

Page 42: ...hen products are returned Valves must be drained before being returned The components have to be delivered free to the following address Bosch Rexroth AG Service Industriehydraulik Industrial Hydraulics Service Bürgermeister Dr Nebel Straße 8 97816 Lohr am Main Germany 12 3 Packaging Upon request reusable systems can be used for regular deliveries The materials for disposable packaging are mostly ...

Page 43: ...ult correction 14 1 How to proceed for troubleshooting Always work systematically and purposefully even when under time pressure In the worst case random thoughtless disassembly and changing settings might result in the inability to identify the original cause of error First get an overview of the functions of the valve in conjunction with the overall system Try to find out whether the valve has w...

Page 44: ... contamination Remove valve and replace it with a new one Have the valve repaired Contact problems at the connection terminal Check the mounting screws of the connection terminal and tighten them using a manual torque wrench Observe the instructions in chapter 7 Assembly External leakage Seal defective Seal at the connection surface is defective Remove the valve and replace the seals Other leakage...

Page 45: ... am Main Germany Phone 49 0 9352 40 50 60 Email service boschrexroth de 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 service and spare parts Headquarters ...

Page 46: ...46 48 Declaration of conformity Bosch Rexroth AG 4WRZ 7X XE RE 29115 XE B 09 19 17 Declaration of conformity ...

Page 47: ... Inspection and maintenance 37 Intended use 9 L List of addresses 45 M Maintenance 37 Maintenance schedule 39 Modification 43 N Name plate 18 Notices on the valve use 15 O Obligations of the machine end user 15 Operation 36 P Personal protective equipment 15 Q Qualification of personnel 11 R Removal 41 Repair 37 39 Required and amending documentation 7 S Safety instructions 9 12 13 Scope of delive...

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 RE 29115 XE B 09 19 ...

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