Bosch Rexroth H-4WEH...XE Series Operating Instructions Manual Download

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Operating instructions
RE 24751-XE-B/04.16

Replaces: 09.13
English

4/2 and 4/3 directional valves,

internally pilot-operated,

externally pilot-operated

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

II 2G

)

Type H-4WEH...XE.

Summary of Contents for Rexroth H-4WEH...XE Series

Page 1: ...RE 24751 XE B 04 16 Replaces 09 13 English 4 2 and 4 3 directional valves internally pilot operated externally pilot operated Area of application according to the explosion protection directive 2014 34 EU II 2G Type H 4WEH XE ...

Page 2: ...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 3: ...duct information 16 5 1 Product identification 17 6 Transport and storage 22 6 1 Transporting the valve 22 6 2 Storing the hydraulic valve 23 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 Before the assembly 25 7 5 Required tools 25 7 6 Required accessories 25 7 7 Assembling the valve 26 8 Commissioning 34 9 Operation 37 9 1...

Page 4: ...E B 04 16 12 5 Recycling 45 13 Extension and modification 45 14 Troubleshooting 46 14 1 How to proceed for troubleshooting 46 15 Technical data 47 16 Appendix 48 16 1 List of addresses 48 17 Declaration of conformity 49 18 Alphabetical index 50 ...

Page 5: ...bol and you have understood and observed it Table 1 Required and amending documentation Title Document number Document type 4 2 and 4 3 directional valves internally pilot operated externally pilot operated 24751 XE Data sheet General product information on hydraulic products 07008 Data sheet Subplates 45100 Data sheet Declaration of conformity H 4WEH XE Document Refer to operating instructions 24...

Page 6: ...gerous situation which may cause death or severe 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 following symbols indicate notices which are not safety relevant but increase the comprehensibility of the documentation Table 3 Mea...

Page 7: ...ly 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 product is a hydraulic component You may use the product as follows as a pilot operated valve with solenoid actuation for intended use in explosive atmospheres The produ...

Page 8: ...ions without the written approval by Bosch Rexroth AG 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 during use which in turn could cause personal injuries and or damage to property Therefore please only use a product for safety...

Page 9: ...ding 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 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 clas...

Page 10: ... 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 during use which in turn could cause personal injuries and or damage to property Therefore only use a product for safety relev...

Page 11: ... may lead to functional failures like e g overheating of the valve solenoid This means that the explosion protection is no longer ensured Only use the valve within the intended environmental and hydraulic fluid temperature range Hot surface at the valve solenoid Risk of burning Provide for a suitable touch guard During operation only touch the valve solenoid using heat protective gloves Allow the ...

Page 12: ...mming or blocking of nozzles of the 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 valve over the entire operating range Leakage in case of incorrect working temperatures Use of the valve outside the approved temperature ranges may lead to...

Page 13: ...line and valve To ensure proper functioning the valve must be bled It must be ensured that the values for the minimum pilot pressure specified in Data sheet 24751 XE Technical data hydraulic are complied with Pressure peaks in the joint return line of more than one valve may cause unintended movements of the control spool and thus unintended switching processes This particularly holds true when va...

Page 14: ...f the Bosch Rexroth valve is responsible that the valve is only 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 24751 XE in particular that the limit values indicated in Data sheet 24751 XE are not exceeded the applicable prov...

Page 15: ...ticles 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 Before commissioning ensure that all hydraulic connections are tight and that all...

Page 16: ... 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 Product information For information on the perfo...

Page 17: ...ves of size 10 Fig 2 Name plate for valves of size 16 25 32 Table 5 Information on the name plate No Type of information Information or example 1 Manufacturer s logo Rexroth 2 Material no of the valve e g MNR R901034038 3 Type designation complete valve e g H 4WEH10H4X 6BW230RNXEDZ2 4 Serial number of the valve e g SN 0002111 5 Manufacturer s factory number e g 7081 6 Date of manufacture year and ...

Page 18: ...h 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 1234567890 14 CE mark CE 15 Explosion protection mark Ex 16 Mark according to the explosion protection directive 2014 34 EU and mark for the type of protection of the mechanical part according to EN 13463 5 II 2G c T4X 17 18 19 95 Rexroth QR code Q...

Page 19: ...C Ta 55 C1 9 Explosion protection mark Ex 10 Type examination certificate number KEMA 02ATEX2240 X 11 Mark for protection class according to explosion protection directive 2014 34 EU II 2G 12 Mark for the type of protection according to EN 60079 7 or EN 60079 18 Ex eb mb IIC T4 Gb 13 CE mark and identification of notified body CE 0158 14 IEC Certificate of Conformity IECEx DEK 12 0068X 15 Mark for...

Page 20: ...tially explosive atmospheres in which explosive gasses 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 Potentially explosive atmospheres in which explosive gasses mists or vapors device group II occur sometimes Corresponds to zone 1 according to directive 1999 92 EC High...

Page 21: ...hat in atmospheres which are potentially explosive due to explosive gasses 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...

Page 22: ...s If transported improperly the valve may fall down and cause damage and or injuries since the parts are e g sharp edged oily unstable loose or bulky Use the original packaging for transport Use personal protective equipment such as gloves working shoes safety goggles working clothes etc Comply with the national laws and regulations regarding occupational health and safety and transport Do not tra...

Page 23: ...alve must be closed with closing elements After opening the transport packaging it must be closed properly again for storage Use the original packaging for storage 1 Check the complete valve for damage 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 com...

Page 24: ...ordance with the national regulations of your country 7 2 Changes to the surface protection of the valve DANGER Explosion hazard caused by changes at the valve Any change at the surface protection of the valve solenoid will lead to loss of the explosion protection The valve solenoid must not be painted or otherwise coated with non conductive substances Additional painting of the valve housing may ...

Page 25: ...ctions 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 in the scope of delivery and can be ordered separately from Bosch Rexroth For reasons of stability exclusively use the following valve mounting screws Table 11 Valve mounting screw...

Page 26: ...e 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 blocks or plates suitable for the weight of the valve Observe the tightening torques screw stabi...

Page 27: ...e 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 6 Place the valve on the contact surface For reasons of stability exclusively use the valve mounting screws specified in chapter 7 6 Required accessories Always fasten the valve with all valve mounting screw...

Page 28: ...the complete machine or system Assemble lines and hoses without stress 1 De pressurize the relevant system part 2 Establish all 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 corr...

Page 29: ...r 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 A wrongly dimensioned fuse protection may lead to overheating and thus cause an explosion A fuse which corresponds to the rated current according to DIN 41571 and ...

Page 30: ...ection and installation observe the provisions of EN 60079 14 Avoid bends in the connection lines and litz wires in order to avoid short circuits and interruptions Only assemble the cable and line entries according to the assembly instructions Check before the assembly whether the individual components of the cable and line entry are complete and whether the sealing elements are undamaged Use fine...

Page 31: ...ble and line entry is already screwed in the terminal box of the valve 1 De energize 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 ferrule on the individual conductors For the stripping lengths refer to fig 5 and table 14 Fig 5 Stripping lengths 1 2 ...

Page 32: ...nipple 2 using an open end wrench wrench size 46 The required tightening torque depends on the line diameter 8 Securely tighten the clamping screws of the pull relief 5 The required tightening torque depends on the line diameter 9 Insert the individual conductors in the connection terminal and screw it on using the clamping screws Tightening torques for the clamping screws Table 15 Tightening torq...

Page 33: ...n staggered assembly around the pole tube i e the longitudinal axis of the valve displaced by 90 The pole tube of the valve solenoid is completely sealed towards the oil circuit The solenoid coil can therefore still be twisted if the valve has already been installed 1 Detach the mounting nut of the valve solenoid at the pole tube hexagon nut wrench size 32 2 Remove the solenoid coil and the O ring...

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 the valve may burst or the closing elements may fly around and cause serious injuries Ensure before the commissioning of the hydraulic system that the maximum admissible pressure of the hydraulic valve in the system is ...

Page 35: ...is may cause damage You can also achieve the switching movement of the valve control spool necessary for the bleeding procedure by manual actuation of the manual override see chapter 9 2 Operating the manual override only relevant for type H 4WEH NXE Ensure that during operation no hydraulic fluid leaks at the valve or at the connections Check whether there is internal leakage This must be done ac...

Page 36: ...type S the throttle is installed in the supply to the main valve With type S2 the throttle is installed in the discharge of the main valve Fig 6 Twin throttle check valve 1 Pilot control valve 2 Twin throttle check valve 3 Main valve Fig 7 Setting the switching time 1 Remove the protective cap wrench size 20 1 2 Loosen the lock nut 3 wrench size 10 3 Change the switching time by rotating the set s...

Page 37: ... assembly if only one of the solenoids is energized at a time and during individual operation the maximum ambient temperature may not exceed 70 C CAUTION Loud noise In case of an unfavorable disposition of valves resonance or fluid noises e g whistling may result In continuous operation these noises may cause hearing damage in persons or damage at the valves In this case contact a service engineer...

Page 38: ...ate the manual override if the pressure in the tank channel of the valve does not exceed 50 bar Above this pressure value the actuating force to be applied is too large Do not use sharp edged tools to operate the manual override Valve type H 4WEH NXE is equipped with a manual override Using this manual override the switching function of the valve can also be triggered if the solenoid is not energi...

Page 39: ...that all seals and caps of the plug in connections are firmly attached so that no humidity can penetrate the valve during cleaning Remove external coarse dirt and keep sensitive and important parts such as valve solenoids clean Remove dust and dirt accumulations on the valve at regular intervals 10 2 Inspection and maintenance WARNING Uncontrolled machine movements Risk of injury due to maintenanc...

Page 40: ...ge and replace the sealing devices if required see chapter 10 5 Rectifying external leakages 6 Open the terminal box and replace any damaged sealing devices if required 7 Check the inside of the terminal box for corrosion Corrosion is an indication of leakage Remove the valve and have it repaired if there is any visible corrosion 8 Check the potting compound of the valve solenoid and internal line...

Page 41: ...he system is switched off depressurized and has cooled down 10 4 Repair DANGER Explosion hazard caused by improper repair In case of improper repair the explosion protection no longer applies in subsequent operation For repair the valve may only be disassembled to the extent described in these operating instructions Defective parts may only be replaced by new interchangeable tested components in o...

Page 42: ... seal kit for the terminal box Spare part Material number Seal kit terminal box contains 1 complete cable and line entry 1 blind plug for the O ring 4 M4 hexagon socket head cap screws for the terminal box 4 spring washers for the terminal box 1 flat seal R961009879 For a valve with two valve solenoids two seal kits are required In case of questions regarding spare parts please contact the compete...

Page 43: ...and cause injuries During the disassembly secure the valve against falling down Have sufficiently dimensioned collecting containers sufficient cleaning cloths and medium binding materials ready in order to collect or bind leaking hydraulic fluid 1 De energize and de pressurize the relevant system part 2 Professionally remove the electrical connections 3 Prepare a container for collecting the leaki...

Page 44: ...of the valve 12 2 Return to Bosch Rexroth AG The hydraulic products manufactured by us can be returned to us for disposal purposes at no costs There must be no inappropriate foreign substances or third party components when products are returned Hydraulic 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 Servic...

Page 45: ...c and electronic assemblies can be recovered by means of special separation procedures as well 13 Extension and modification DANGER Explosion hazard caused by unauthorized modification Any unauthorized modification results in the loss of the explosion protection Modifications exceeding the extent described in these operating instructions are not permitted With valves with only one valve solenoid t...

Page 46: ...ry to find out whether the valve has functioned properly in conjunction with the overall system before the error occurred first Try to determine any changes to the overall system in which the valve is integrated Were there any changes to the application conditions or to the area of application of the valve Have any changes e g refittings been made or have repair works been carried out at the overa...

Page 47: ...ve valve and replace it with a new one Required minimum pilot pres sure is not achieved Check whether the pressure at port X with external pilot oil supply or at port P with internal pilot oil supply achieves the value for the minimum pilot pressure specified in the Data sheet 24751 XE technical data hydraulic Restoring the minimum pilot pressure Pilot pressure is too high 250 bar Reduce the pilot...

Page 48: ...ermany Phone 49 93 52 40 50 60 Email repair hydraulics boschrexroth de Headquarters Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Phone 49 93 52 18 0 Email info 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 accessories and ...

Page 49: ...Declaration of conformity 49 52 RE 24751 XE B 04 16 H 4WEH XE Bosch Rexroth AG 17 Declaration of conformity ...

Page 50: ...ance schedule 41 Main valve 36 Manual override 38 Modification 45 N Name plate 17 O Obligations of the machine end user 14 Operation 37 P Packaging 44 Pilot control valve 36 Protective equipment 14 Q Qualification of personnel 9 R Recycling 45 Removal 43 Repair 39 41 Required and amending documentation 5 Risk classes 6 S Safety instructions 5 7 Scope of delivery 16 Spare parts 42 Storage 22 Stripp...

Page 51: ...Alphabetical index 51 52 RE 24751 XE B 04 16 H 4WEH XE Bosch Rexroth AG ...

Page 52: ...Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Phone 49 9352 18 0 info boschrexroth de www boschrexroth com Subject to change without notice Printed in Germany RE 24751 XE B 04 16 ...

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