Bosch Rexroth DBA 1X E Series Operating Instructions Manual Download Page 53

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RE 25880-B/10.18, DBA...1X/...E, Bosch Rexroth AG

Summary of Contents for Rexroth DBA 1X E Series

Page 1: ...Operating instructions RE 25880 B 10 18 Replaces 09 17 English Mat no R901442022 Pump safety block Safety valve according to Pressure Equipment Directive 2014 68 EU Type DBA 1X E ...

Page 2: ...υς 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 caso contrario diríjase a su persona de contacto en Bosch Rexroth ...

Page 3: ...reendido 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 î...

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: ... 20 5 3 Limitations of use 20 6 Transport and storage 21 6 1 Transporting the product 21 6 2 Storing the safety valve 22 7 Assembly 23 7 1 Unpacking 24 7 2 Installation conditions 24 7 3 Painting the valve housing 24 7 4 Necessary tools 24 7 5 Accessories 25 7 6 Prior to assembly 26 7 7 Assembly of the safety valve 27 7 8 Additional M port 30 7 9 Connecting the power supply only with type DBAW 1X ...

Page 6: ...eturn to Bosch Rexroth AG 45 12 3 Packaging 45 12 4 Materials used 45 12 5 Recycling 46 13 Extension and modification 46 14 Troubleshooting 46 14 1 How to proceed for troubleshooting 46 14 2 List of addresses 50 15 Declaration of conformity 51 16 Index 52 ...

Page 7: ...ion marked with the book symbol and you have understood and observed it Table 1 Necessary and amending documentation Title Document number Document type Hydraulic valves for industrial applications 07600 B Operating instructions Pump safety block 25880 Data sheet Mating connectors and cable sets for valves and sensors in hydraulics 08006 Data sheet Setting certificate is included in the scope of d...

Page 8: ...ing 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 personal injury if not avoided CAUTION Indicates a dangerous situation which may cause minor or moderate personal injury if not avoided NOTICE Damage to property The product or the environment could be damaged 1 3 2 Symbols The fo...

Page 9: ... damage to property if you do not observe this chapter and the safety instructions in this documentation Read this documentation completely and thoroughly before working with the product Keep this documentation in a location 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 valves comply wit...

Page 10: ...enance operation Their position must not be changed they must not be circumvented or made ineffective 2 3 Improper use The safety valve is not suitable for use in potentially explosive environment it must not be used there The safety valve may not be used if the maximum possible flow of the system in all imaginable operating states exceeds the value indicated in the technical data for the relevant...

Page 11: ...nd an overview of the training contents on the Internet at http www boschrexroth de didactic 2 5 General safety instructions Observe the valid regulations on accident prevention and environmental protection Observe the safety regulations and provisions of the country in which the product is used applied Exclusively use Rexroth products in technically perfect condition Observe all notices on the pr...

Page 12: ...ergy supply persons may be caught by the system kicked away or bruised When setting up your circuit observe functional safety e g according to EN ISO 13849 Faulty mounting Mounting of the safety valve with valve mounting screws of reduced stability or insufficient mounting at installation surfaces pump with insufficient stability may cause the safety valve to become loose and fall down Consequentl...

Page 13: ...tional failures of the safety valve In the worst case this may result in unexpected system movements and thus constitute a risk of injury for persons Ensure adequate hydraulic fluid cleanliness according to the cleanliness classes of the safety valve over the entire operating range Exceedance of the maximum temperatures Use of the safety valve outside the temperature intended for that purpose may ...

Page 14: ...se as defined in these operating instructions the operating personnel are instructed at regular intervals a danger zone is marked if required the safety measures for their specific area of application of the safety valve are complied with the safety valve is only stored operated and maintained according to the technical data operating and environmental conditions indicated in these operating instr...

Page 15: ...put any objects on top of it Dirt and foreign particles in hydraulic components Penetrating dirt and foreign particles lead to wear and malfunctions Safe function of the safety 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 Do not use linting fabric f...

Page 16: ...mpleteness 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 section 14 2 List of addresses Accessories such as valve mounting screws are not included in the scope of delivery they can however be ordered separately See chap 7 5 Accessories 5 Product information For information on the performance a...

Page 17: ...r 12 Customer s or production order number 2 14 CE mark 3 18 Component marking 19 Reference number of the testing authority 95 Rexroth QR code 1 Consecutively assigned code number for valves from a production order 2 Consecutively assigned number This number is identical with the valve no in the related certificate regarding the setting of safety valves setting certificate and thus allows for the ...

Page 18: ...n of origin 11 Name and address of the manufacturer 12 Customer s or production order number 2 14 CE mark 3 18 Component marking 19 Reference number of the testing authority 95 Rexroth QR code 1 Consecutively assigned code number for valves from a production order 2 Consecutively assigned number This number is identical with the valve no in the related certificate regarding the setting of safety v...

Page 19: ...he manufacturer 12 Customer s or production order number 2 14 CE mark 3 18 Component marking 19 Reference number of the testing authority 95 Rexroth QR code 1 Consecutively assigned code number for valves from a production order 2 Consecutively assigned number This number is identical with the valve no in the related certificate regarding the setting of safety valves setting certificate and thus a...

Page 20: ...y valves may only be operated within certain limitations of use see Data sheet 25880 The maximum admissible flow in l min can always been seen from the last but one figure of the component marking In the plant the response pressure specified in the component marking is set with a flow of 11 l min The component marking is located on the name plate The maximum admissible flow stated in the component...

Page 21: ...y and transport Heavy components When lifting a safety valve with high weight there is the danger of health hazards Use a suitable lifting putting down and moving technique Products 15 kg are usually provided with lifting eyes for transport by means of lifting gear Use these lifting eyes Transport the safety valve complying with the safety instructions and using a forklift or suitable lifting gear...

Page 22: ...2 months under the following conditions Ensure a storage temperature range of 5 40 C The relative air humidity may not exceed 65 The storage rooms must provide 100 UV protection No ozone formation may occur near the storage facility The storage facilities must be free from etching substances and gases Do not store the safety valve outdoors but in a well ventilated room Protect the safety valve aga...

Page 23: ...g Danger of component damage Insufficient installation space may lead to jamming or abrasions in case of actuation or adjustment works at the safety valve Components cannot be properly mounted or might be damaged Make sure that the assembly space is sufficient NOTICE Penetrating humidity The housing of the valve electronics is closed however according to the applicable protection class fluids may ...

Page 24: ... must be protected from dirt during installation Contamination of the hydraulic fluid may considerably reduce the life cycle of the safety valve 7 2 1 Installation position The installation position is not relevant 7 3 Painting the valve housing Completely protect the hydraulic ports against paint application by screwing in plastic screw in plugs Protect the mounting bores against paint applicatio...

Page 25: ...suppression circuit 24 V gray R901017010 black R901017011 R901017022 R901017025 R901017026 Table 8 Valve mounting screws for standard flanges types DBA F and DBAR F Size Type Dimensions Material number 32 DBA M10 x 120 R913000074 DBAR M10 x 125 R913000668 40 DBA M12 x 135 R913024229 DBAR M12 x 140 R913000312 Table 9 Valve mounting screws for high pressure flanges types DBA H and DBAR H Size Type D...

Page 26: ...he cleanliness of the hydraulic fluid has a considerable impact on the cleanliness and life cycle of the safety valve Any contamination of the hydraulic fluid will result in wear and malfunctions Particularly foreign particles may damage the safety valve Always ensure absolute cleanliness Install the safety valve free from any pollution Make sure that all connections hydraulic lines and attachment...

Page 27: ...s may be used Screw dimensions property classes and tightening torques depend on the valve type and the size Mount valves with flange connection 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 are absorbed by the fixation in a risk free manner Faulty assembly In case of faulty assembly due to a mix ...

Page 28: ...torque wrench For the tightening torques please refer to the tables below 6 Please note that the tightening torques may change if other screw types are used Table 10 Information on valve mounting screws for standard flanges types DBA F and DBAR F 1 Valve mounting screws ISO 4762 10 9 flZn 240h L at friction coefficient µtotal 0 09 0 14 2 The tightening torques are guidelines for the specified fric...

Page 29: ...cted to port T The connection surfaces of the valve and the valve installation surface must be clean and free from hydraulic fluid Use non linting fabric for cleaning the valve installation surface 1 Tighten pipe fittings which are screwed directly into the safety valve Observe the tightening torque information by the pipe fitting manufacturer Table 12 Type of pipe fitting Valve type size Componen...

Page 30: ... tightening torque specified by the pressure gauge manufacturer to install the pressure gauge To seal the port again using the plug screw the screw must be tightened using the tightening torque specified in table 13 Table 13 M port information on the plug screw Valve type size Component marking DBA30 1X E 1150 DBA40 1X E 1150 Fitting of hydraulic connections valves with pipe thread according to EN...

Page 31: ...ent of the supply voltage source The fuse may be accommodated in the related supply unit or must be separately connected upstream Missing equipotential bonding Electrostatic processes an incorrect earthing concept or missing equipotential bonding may lead to malfunctions or uncontrolled movements at the machine and thus cause injuries Provide for correct earthing and provide for proper equipotenti...

Page 32: ...aulic fluid Carelessly or incorrectly fastened safety valves may become loose during operation fall down and cause serious injuries A hydraulic fluid jet may leak at incompletely mounted hydraulic connections and connection lines and cause serious injuries Only commission the system after all hydraulic connections and the safety valve have been completely and properly mounted according to the spec...

Page 33: ...rride For further information see chapter 9 4 Operating the optional manual override at the directional valve Check whether during operation hydraulic fluid leaks at the safety valve and at the connections 9 Operation WARNING Incorrect area of application The approval according to Pressure Equipment Directive and thus the safe pressure relief function are no longer applicable if the safety valve i...

Page 34: ...ally closed by a plug screw The response pressure of a safety valve may only be within the specified pressure range due to the installed compression spring The maximum flow indicated by the component marking can only be utilized within this pressure range 1 Temporarily deactivate or remove any other pressure relief devices which are installed in the system and have an impact on channel P and seal ...

Page 35: ...ssure in the discharge line In principle the safety valve should be operated without counter pressure in the discharge line if possible The following applies to valves with external pilot oil discharge i e valves with Y port without counter pressure in pilot oil return line Admissible counter pressure in the discharge line port T 10 bar The following applies to valves with internal pilot oil disch...

Page 36: ...E with different response pressures pA with internal pilot oil discharge Table 15 Counter pressure diagram DBA30 1X E pA response pressure in bar pT maximum admissible counter pressure in the discharge line port T in bar qVmax maximum flow in l min pTmax 10 x pA with qV 0 l min Table 16 Assignment characteristic curve response pressure pA Characteristic curve Response pressure pA in bar 1 30 2 60 ...

Page 37: ...ar pT maximum admissible counter pressure in the discharge line port T in bar qVmax maximum flow in l min pTmax 10 x pA with qV 0 l min Table 18 Assignment characteristic curve response pressure pA Characteristic curve Response pressure pA in bar 1 30 2 60 3 65 4 110 5 115 6 210 7 215 8 350 Characteristic curves for intermediate values can be generated by interpolation Flow of the system accumulat...

Page 38: ...of damaging the valve and or incorrect operation may result in dangerous movements of the connected actuators Only operate the manual override if it is ensured that this will not trigger any dangerous working movement of the connected actuator Do not use sharp edged tools to operate the manual override There is the danger of damaging sealing surfaces at the solenoid The manual override is only int...

Page 39: ...irt and keep sensitive and important parts clean Only clean the safety valve using a damp non linting cloth Only use water and a mild cleaning agent if necessary to do so 10 2 Inspection and maintenance NOTICE Dirt and foreign particles in the safety valve Penetrating dirt and foreign particles in the safety valve lead to wear and malfunctions Safe function of the safety valve is therefore no long...

Page 40: ...ty valves of type DBAW 1X E We recommend replacing the seals between main and directional valve which are intended for exchange by new ones at regular intervals To this end main and directional valve must be separated from each other Observe the tightening torques for the valve mounting screws which are to be complied with in the case of re assembly after seal exchange see table 20 For more inform...

Page 41: ...t particles that might exist at the valve seat are removed by the flow 5 Screw in the adjustment spindle 2 by rotating the rotary knob 3 clockwise so that the lock nut 1 rests against the valve body without any play If the response pressure is to be newly set rotate the adjustment spindle so that at a suitable calibrated pressure gauge with the largest accuracy possible the original response press...

Page 42: ...m 10 3 Repair WARNING Damage to persons and property caused by improper repair In case of improper repair the safety function of the safety valve is no longer given in subsequent operation Only repair measures listed in chapter 10 Maintenance and repair are admissible Only qualified personnel see chapter 2 4 Qualification of personnel is authorized to repair the safety valve The sealing and or the...

Page 43: ...or connection of main housing to attached valve elements at type DBAW 1X E Valve type Screw type Tightening torque MA 1 DBAW 1X 6E E 4 hexagon socket head cap screws ISO 4762 M5 x 50 10 9 MA 7 0 7 Nm1 2 DBAW 1X 6SM E 4 hexagon socket head cap screws ISO 4762 M5 x 85 10 9 MA 7 0 7 Nm1 2 DBA R 1X E 2 cheese head screws ISO 1580 M4 x 10 4 8 MA hand tight 1 Friction coefficient µ 0 09 to 0 14 2 Tighte...

Page 44: ...y works 2 Unload the hydraulic accumulators if applicable 3 Provide for a clean environment during the disassembly 4 Prepare a container or a pan for collecting the leaking hydraulic fluid 5 Detach the safety valve from the pipelines flange connections or the valve installation surface using appropriate tools collect any hydraulic fluid that might leak in the provided tank Dispose of the hydraulic...

Page 45: ...re returned Safety valves have to be drained before being returned The components have to be sent free to the door 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 most...

Page 46: ...ne the original cause of error First get a general idea of how the safety valve works in conjunction with the overall system Try to find out whether the safety valve has worked properly in conjunction with the overall system before the error occurred first Try to determine any changes of the overall system in which the safety valve is integrated Were there any changes to the safety valve s applica...

Page 47: ...ee EC Pressure Equipment Directive 2014 68 EU Appendix I chap 7 3 A safety valve with insufficiently dimensioned flow was installed Select and order a safety valve with suitable specified flow The T port of the safety valve is connected via a line with excessive flow resistance Use larger discharge pipes increase outlet diameters avoid a deflection of flow observe the maximum admissible counter pr...

Page 48: ...ou are not successful replace the safety valve Safety valve oscillates Together with other components the safety valve constitutes an oscillating system in which there are regulating oscillations A safety valve may not be used as a high response valve Sealing is damaged or missing The lead seal has been destroyed by the operating personnel or mechanical influence The safety valve may not be re sea...

Page 49: ...e directional valve or at the switching shock damping valve Directional valve switching shock damping valve defective Send valve to the authorized facility for repair Please contact your regional Bosch Rexroth representative Rotary handle is destroyed Transport damage improper handling Send valve to the authorized facility for repair Please contact your regional Bosch Rexroth representative Valve ...

Page 50: ...exroth com adressen A possibly missing setting certificate can be requested from the Rexroth Quality Assurance at the following address Bosch Rexroth AG Department LoP1 QMM7 Zum Eisengießer 1 97816 Lohr am Main Phone 49 9352 18 3631 3447 Email LoP1QMM7 Abteilungspostfach boschrexroth de Internet www boschrexroth de In your request please specify the production number the date of manufacture and th...

Page 51: ...Declaration of conformity 51 56 RE 25880 B 10 18 DBA 1X E Bosch Rexroth AG 15 Declaration of conformity ...

Page 52: ...tion position 24 Intended use 9 L Lifting gear 22 Limitations of use 20 M Maintenance 39 Maintenance interval 40 Manual override 38 Modification 46 M port 30 N Name plate 17 O Obligations of the machine end user 14 Operation 33 Order confirmation 26 P Pressure gauge 34 Pressure range 34 Protective equipment 14 Q Qualification 11 R Repair 39 Required documentation 7 Response pressure 34 S Safety in...

Page 53: ...Index 53 56 RE 25880 B 10 18 DBA 1X E Bosch Rexroth AG ...

Page 54: ...54 56 Index Bosch Rexroth AG DBA 1X E RE 25880 B 10 18 ...

Page 55: ...Index 55 56 RE 25880 B 10 18 DBA 1X E Bosch Rexroth AG ...

Page 56: ...osch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Phone 49 0 9352 40 30 20 my support boschrexroth de www boschrexroth com Subject to change without notice Printed in Germany RE 25880 B 10 18 ...

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