Bosch Rexroth DB 5X XC Series Operating Instructions Manual Download

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Operating instructions
RE25802-XC-B/07.19

Replaces: 10.17
Document no.: RA78451570_AA
English

Pressure relief valve,

pilot-operated

(Area of application in accordance with the explosion protection directive
2014/34/EU:

IM2; II2G; II2D

)

Type DB...5X/...XC

Summary of Contents for Rexroth DB 5X XC Series

Page 1: ...e Operating instructions RE25802 XC B 07 19 Replaces 10 17 Document no RA78451570_AA English Pressure relief valve pilot operated Area of application in accordance with the explosion protection directive 2014 34 EU IM2 II2G II2D Type DB 5X XC ...

Page 2: ... 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 c...

Page 3: ...preendido 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: ...ligation of own judgment and verification Our products are subject to a natural process of wear and aging This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent The cover shows an example configuration The product supplied may therefore differ from t...

Page 5: ...ry 17 5 Product information 18 5 1 Product identification 18 6 Transport and storage 20 6 1 Valve transport 20 6 2 Storing the hydraulic valve 20 7 Assembly 22 7 1 Unpacking 22 7 2 Changes at the surface protection of the valve 22 7 3 Installation conditions 22 7 4 Prior to assembly 23 7 5 Required tools 23 7 6 Required accessories 23 7 7 Assembling the valve 24 8 Commissioning 28 9 Operation 29 9...

Page 6: ...on and modification 37 13 1 Modification of the valve to solenoid actuated unloading 37 14 Troubleshooting and fault correction 39 14 1 How to proceed for troubleshooting 39 15 Technical data 41 16 Appendix 41 16 1 List of addresses 41 17 Declaration of conformity 42 18 Index 43 ...

Page 7: ...uct must 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 Pressure relief valve pilot operated 25802 XC Data sheet Subplates 45100 Data sheet Declaration of conformity DB 5X XC Document refer to chapter 17 1 3 Representation of i...

Page 8: ...ation which may cause death or severe injury if not avoided CAUTION 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 notes which are not safety relevant but increase the comprehensibility of the documentation Table 3 Meaning of the sym...

Page 9: ... where it is accessible to all users at all times Always include the required documentation when you pass the product on to third parties 2 2 Intended use The product is a hydraulic component You may use the product as follows as a pilot operated pressure relief valve for intended use in explosive atmospheres The product is only intended for professional use and not for private use Intended use in...

Page 10: ...ted or made ineffective 2 3 Improper use Any use deviating from the intended use is improper and thus not admissible 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 please only use a product for safety relevant applications if...

Page 11: ...pletely 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 The personnel must have the following additional qualifications to the extent required to fulfill their tasks Understanding of the general principles of explosion protection protection classes and devi...

Page 12: ...ries and spare parts in order to prevent any 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 prope...

Page 13: ...tion only touch the valve using heat protective gloves Allow the valve to cool down to room temperature before touching it directly with your hands during maintenance work Pressurized system parts and leaking hydraulic fluid When working at hydraulic systems with stored energy accumulator or cylinders working under gravity valves may even be pressurized after switching off the pressure supply Duri...

Page 14: ...on The valve described has surface protection see Data sheet 25802 XC Use of the valve in humid environments still holds the danger of corrosion on the valve and on the valve mounting screws and thus a reduction of the preload force of the screw connection To prevent the valve from becoming loose and causing a risk of injury Exchange the valves with corrosion damages as soon as possible Check the ...

Page 15: ...nd 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 25802 XC in particular that the limit values indicated in Data sheet 25802 XC are not exceeded the ...

Page 16: ...ndle or a 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 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 lines Befo...

Page 17: ...on of conformity and data sheet Check the 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 c...

Page 18: ...on on the name plate 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 manufacture year and week 7 Maximum operating pressure 8 Ambient temperature range 9 Hydraulic symbol according to ISO 1219 10 Designation of origin 11 Name and address of the manufacturer 12 Customer s...

Page 19: ... device group I i e underground mines and their pitheads If there is an explosive atmosphere it must be possible to switch off the device High 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 level of safety 0 1 2 II 2G Po...

Page 20: ... addresses Notify your responsible sales contact person any transport damage within one week The addresses of the sales subsidiaries can be found on the Internet at http www boschrexroth com adressen 6 2 Storing the hydraulic valve Valves are delivered in a perfect state For transporting and storing the product always observe the environmental conditions specified in Data sheet 25802 XC Improper s...

Page 21: ...y your competent Bosch Rexroth service In case of questions regarding spare parts please contact the Bosch Rexroth service responsible for your valve see chapter 10 6 Spare parts If a dismounted valve is to be stored it has to be preserved for protection against corrosion for the duration of storage Bosch Rexroth recommends the following procedure 1 Clean the valve refer to chapter 10 1 Cleaning a...

Page 22: ...top The main stage has been sealed with the pilot stage of the valve by the manufacturer Check whether the sealing is undamaged Dispose of the packaging in accordance with the national regulations of your country 7 2 Changes at the surface protection of the valve WARNING Explosion hazard due to insufficient heat dissipation Dissipation of the valve heat must not be obstructed This means that the e...

Page 23: ...e sealing is undamaged Transport protection elements e g cover plates protective plugs must be removed prior to use in an explosive atmosphere Apart from that plastic caps are not admissible for use in explosive atmospheres 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 Thes...

Page 24: ...r fastening at blocks and plates with insufficient stability may cause the valve to become loose and fall down Consequently hydraulic fluid may leak and lead to personal injuries and or damage to property Special care must be taken with valves with suspended installation Completely assemble the valve according to the assembly specifications using suitable assembly aids Only assemble the valve at b...

Page 25: ...turns in case any repairs become necessary later 4 Dry the valve connection surface using suitable cleaning materials 5 Check the seal rings at the valve connection surface for completeness Other sealants are not admissible CAUTION Faulty assembly Swapping the ports may cause damage to the valve in case of pressurization Check whether with version Y optional the return line is connected to Y If su...

Page 26: ...nnection WARNING Faulty assembly A valve with threaded connection which you install under high mechanical load generates additional forces during operation which reduce the life cycle of the valve and of the overall machine or system Mount the valve in a way that ensures that reaction forces which act on the valve e g due to vibration shock and hydraulic forces which act on the connection lines in...

Page 27: ... connections In this connection observe 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 at the pipe fittings and flanges Mark all checked fittings e g using a permanent marker 5 Make sure that all pi...

Page 28: ...ve Make sure that all hydraulic connections are closed Commission the valve only if it is completely installed Immediately depressurize the system if hydraulic fluid still leaks despite proper assembly and continue with chapter 14 Troubleshooting To make sure that the maximum admissible pressure for the relevant system is not exceeded during initial commissioning the valve must be set to the minim...

Page 29: ...lt 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 25802 XC The machine and or system manufacturer is responsible for the correct project planning of the hydraulic system and its control Modifications of settings on the valve are not admiss...

Page 30: ...itional measuring port which is normally sealed by a plug screw This does not apply to type DB G 5X X 1 Deactivate or remove any other pressure limiting functions of the system which act on the pressure port P Seal any resulting openings if required 2 With systems without installed pressure gauge connect a pressure gauge to the measuring port in the line which leads to the pressure port see Data s...

Page 31: ...isplaces the oil from the hydraulic system and seals Do not use high pressure washers for cleaning For cleaning and care of the valve observe the following Close all openings with appropriate protective caps devices Ensure that all seals are firmly attached so that no humidity can penetrate the valve during cleaning Remove external coarse dirt and keep sensitive and important parts clean Remove du...

Page 32: ...ace the seals if required see chapter 10 5 Rectifying external leakage For order details regarding the seal kits refer to chapter 10 6 Spare parts 3 Check all external fittings for completeness and firm seat 4 Check the valve function regarding the application conditions 10 3 Maintenance schedule Valves require low maintenance when you use them as intended For a long and reliable operation of the ...

Page 33: ...essure decrease and relieve any pressure accumulators if applicable 2 Remove the safety valve see chapter 11 Disassembly and removal 3 Check whether the recesses for the seal rings at the valve connection surface are clean and intact 4 Dry the valve connection surface and the valve contact surface using suitable cleaning materials 5 Assemble the new seals observe the suitability of the seal materi...

Page 34: ...ease contact your responsible Bosch Rexroth Service Bosch Rexroth AG Service Hydraulics Bürgermeister Dr Nebel Str 8 97816 Lohr am Main Tel 49 0 9352 40 50 60 service boschrexroth de For the addresses of our sales and service network please refer to www boschrexroth com adressen 11 Disassembly and removal WARNING Danger of damage to property and personal injuries at energized or pressurized system...

Page 35: ...crews of the valve and remove them 8 Collect escaping hydraulic fluid in the provided container and dispose of it properly 9 If the valve is to be returned to the manufacturer for repair close the valve connection surface using the protective plate supplied or seal the ports using protective covers or equivalent packaging in order to avoid contamination and damage 10 Seal the subplate and or the p...

Page 36: ...aging are mostly cardboard wood and expanded polystyrene They can be recycled without any problems For ecological reasons disposable packaging should not be used for returning products to Bosch Rexroth 12 4 Materials used Hydraulic components from Bosch Rexroth do not contain any hazardous materials that could be released during intended use Normally no negative effects on human beings and on the ...

Page 37: ...solenoid actuated unloading may cause an explosion Prior to modification it must be checked whether category and protection class which result from the combination of pressure relief valve and directional valve meet the requirements of the relevant potentially explosive area See Data sheet 25802 XC solenoid actuated unloading Other modifications are not admissible In particular the pilot control v...

Page 38: ... plate 2 including sealing plate 3 from the pressure relief valve 2 Check whether the seals and sealing surfaces are intact The directional valve may only be mounted if the sealing surfaces and seals are intact Seals are included in the scope of delivery of the directional valve 3 Assemble the directional valve In this connection observe the operating instructions of the directional valve Only the...

Page 39: ...arent Try to get a clear idea of the cause of error Ask the direct machine operator if necessary The valve is not sensitive to faults as long as the specified application conditions are complied with in particular the oil quality and the operating temperature Table 11 Fault table Error Possible cause s Remedy Desired operating pressure cannot be set Spring broken Material fatigue Material defect R...

Page 40: ...rding to the spare parts list see chapter 10 6 Spare parts and replace the seal ring Install the valve according to the specifications in chapter 7 Assembly Leakage at the transition from the pilot control valve to the attached directional valve Seal between the pilot control valve and the directional valve is worn Check whether the sealing surfaces and seals are intact Damaged seals may not be us...

Page 41: ...h AG Bürgermeister Dr Nebel Straße 8 97816 Lohr 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 Headqua...

Page 42: ...42 44 Declaration of conformity Bosch Rexroth AG DB 5X XC RE25802 XC B 07 19 17 Declaration of conformity ...

Page 43: ... 31 Installation conditions 22 Intended use 9 L List of addresses 41 M Maintenance schedule 32 Modification 37 N Name plate 18 O Obligations of the machine end user 15 Operation 29 P Personal protective equipment 15 Q Qualification of personnel 11 R Recycling 36 Removal 34 Repair 31 33 Representation of information 7 Required accessories 23 Required tools 23 Response pressure 30 Risk classes 8 S S...

Page 44: ...osch Rexroth AG Zum Eisengießer 1 97816 Lohr a Main Germany Phone 49 0 9352 40 30 20 my support boschrexroth de www boschrexroth com Subject to change without notice Printed in Germany RE25802 XC B 07 19 ...

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