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RE 63124-B, Edition: 08.2021, Bosch Rexroth AG

Commissioning |

Press modules Type IH04 31/56

8 Commissioning

WARNING

Leakage of hydraulic fluid due to incorrectly mounted press module!

Danger to life! Risk of injury!

▶ Only commission your machine/system after all hydraulic connections and the

press module have been completely and properly mounted according to the
specifications.

▶ Look out for defective sealing points and replace defective seal rings

immediately.

▶ Wear personal protective equipment during the initial commissioning.

Bursting of the press module or ejection of the cap elements due to
inadmissible operating pressure!

Danger to life! Risk of injury! Danger of bursting!

▶ Before commissioning the hydraulic system, ensure that the maximum

admissible pressure of the hydraulic components in the machine/system
cannot be exceeded.

▶ Ensure that in your machine/system, the maximum admissible operating

pressure is secured by means of pressure limitation equipment.

NOTICE

Uncontrolled connection or disconnection of electrical component plug-in
connectors!

Damage to property!

▶ Before installation works, separate the press module from the mains or from the

voltage source or de-energize it.

▶ Do not plug in or pull off the electric plug-in connector as long as the voltage

supply is activated.

Wear and malfunctions caused by contaminated hydraulic fluid!

Damage to property!

▶ During commissioning, absolute cleanliness must be ensured.

▶ Make sure that the hydraulic system is only filled with a filtered hydraulic fluid.

▶ Ensure that no contaminations are able to penetrate when sealing the ports.

For commissioning of the press module, always observe the operating
instructions of the overall machine/system.

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Summary of Contents for Rexroth IH04

Page 1: ...General operating instructions RE 63124 B Edition 08 2021 Replaces EN Press modules for hydraulic presses Type IH04 ...

Page 2: ...nt and verification It must be remembered that our products are subject to a natural process of wear and aging All rights are reserved to Bosch Rexroth AG also regarding any disposal exploitation reproduction editing distribution as well as in the event of applications for industrial property rights The cover shows an example configuration The product supplied may therefore differ from the figure ...

Page 3: ... the machine manufacturer 15 2 9 Obligations of the machine end user 15 3 General information on damage to property and damage to product 16 4 Scope of delivery 18 5 Product information 19 5 1 Product description 19 5 2 Normative description 19 5 3 Product identification 19 6 Transport and storage 20 6 1 Transporting the press module 20 6 1 1 Use of attachment points 21 6 1 2 Transport using forkl...

Page 4: ... 12 1 Required tools 41 12 2 Preparing for disassembly 41 12 3 Disassembly process 42 13 Disposal 43 13 1 Environmental protection 43 13 2 Return to Bosch Rexroth AG 43 13 3 Packaging 43 13 4 Materials used 43 13 5 Recycling 44 14 Extension and modification 45 15 Troubleshooting 46 15 1 How to proceed for troubleshooting 46 16 Technical data 48 17 Glossary 49 17 1 General terms for press component...

Page 5: ... number Document type Press module type IH04C 63142 Data sheet Assembly instructions for press modules type IH04C1 Assembly instructions Press module type IH04D 63125 Data sheet Assembly instructions for press modules type IH04D1 Assembly instructions Press modules type IH04E 63129 Data sheet Assembly instructions for press modules type IH04E1 Assembly instructions Press modules type IH04N1 Data s...

Page 6: ...sures described for hazard avoidance must be observed Safety instructions are structured as follows SIGNAL WORD Type and source of danger Consequences in case of non compliance Hazard avoidance measures Enumeration Warning sign Draws attention to the danger Signal word Identifies the degree of danger Type and source of danger Specifies the type and source of danger Consequences Describes the conse...

Page 7: ... product cannot be optimally used and or operated Individual independent action 1 2 3 Numbered instruction The numbers indicate that the actions must be carried out one after the other 1 3 3 Abbreviations The following abbreviations are used in this documentation Table 4 Abbreviations Abbreviation Meaning AOS Active opto electronic safeguard BDC Bottom dead centre BWS Contactless safeguard RE Rexr...

Page 8: ...ic controls on hydraulic drives which generate mechanical movements It is therefore essential for the manufacturer of the overall machine system to have undertaken an independent risk assessment Furthermore the manufacturer must on this basis have prepared operating instructions for the overall machine system These operating instructions do not serve as replacement of the operating instructions of...

Page 9: ...asic safety and health requirements of Directive 2006 42 EC The press module is technical work equipment and not intended for private use Intended use includes having read and understood this documentation especially chapters 2 Safety instructions and 3 General information on damage to property and damage to product 2 3 Improper use Any use deviating from the intended use is improper and thus not ...

Page 10: ...und online at www boschrexroth com de de academy 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 Only use Rexroth products in technically perfect condition Observe all notes on the product Persons who assemble operate disassemble or mai...

Page 11: ...orm special functions danger of entrapment hazard due to being caught in moving parts of the machine separating protective devices motor and drive machinery mechanical handling equipment ejection of machine components Pay attention to the main hazard zones specified in par 4 of EN ISO 16092 and EN 289 standards such as die area with moving parts mechanical handling devices The installation of the ...

Page 12: ... off switch Identify and remedy the leakage Never try to stop or seal the leakage or the oil jet using a cloth Avoid direct contact with the leaking hydraulic fluid Use your personal protective equipment e g safety goggles Do not use the press module in areas with open fire e g ignition sources and only at a sufficient distance to hot heat sources When dealing with hydraulic fluids you must implic...

Page 13: ...easures of the system manufacturer If necessary attach protective covers Contact with hydraulic fluid Health hazard impairment of health e g eye injuries skin lesions poisoning due to inhalation and swallowing Avoid contact with hydraulic fluids When dealing with hydraulic fluids you must implicitly observe the safety instructions of the hydraulic fluid manufacturer Use your personal protective eq...

Page 14: ...and lines in order to prevent them from getting loose due to vibrations Do not assemble hydraulic hoses close to heat sources Malfunction or unexpected system movements due to functional failures e g jamming of valve spools leakage in poppet seats or clogging of nozzles due to contaminated hydraulic fluid Risk of injury Comply with the cleanliness classes required in the relevant data sheet If nec...

Page 15: ...e modified or replaced by the machine end user the intervals for the replacement of safety relevant components the frequency of checking for external leakage the frequency and procedure for testing the function of the hydraulic system to detect internal leakages the maximum weight and the maximum dimensions of the tools which may used for the press 2 9 Obligations of the machine end user The machi...

Page 16: ...articles e g welding beads or metal chips from getting into the hydraulic lines and causing wear or malfunctions at the press module Make sure that all connections hydraulic lines and attachment parts e g valves are clean and free of chips For removing lubricants or any other contamination use industrial residue free wipes No contamination must enter when closing the connections Before commissioni...

Page 17: ...tion of the ground water Immediately remedy possible leakage If hydraulic fluid is spilled use an oil binding agent Observe the information in the safety data sheet of the hydraulic fluid and the system manufacturer s provisions Environmental pollution caused by incorrect disposal Environmental pollution Damage to property Dispose of the press module the hydraulic fluid and the packaging in accord...

Page 18: ...ation General operating instructions for press modules Product specific documentation Type specific assembly instructions for the press module Type specific data sheet for the press module Hydraulic circuit diagram Parts list Installation drawing 1 For further information on the supplied documentation refer to chapter 1 2 Required and additional documentation The warranty only applies to the deliv...

Page 19: ...ional documentation Required and additional documentation and chapter 4 Scope of delivery 5 2 Normative description The press module is a hydraulic control according to EN ISO 4413 EN ISO 16092 and EN 289 consisting of a basic module safety related hydraulic valves with limit switches assembled extension module s if required 5 3 Product identification The press module can be identified by its name...

Page 20: ...rushing Damage to property Wear your personal protective equipment Use original packaging for transport crate with plate fixation if possible Use the intended two attachment points when lifting without packaging see Fig 3 Check the weight with packaging from the delivery note and without packaging from the assembly drawing Determine the position of the center of gravity and ensure a stable loading...

Page 21: ...and or inappropriate attachment points Danger to life Risk of injury Danger of crushing Damage to property Use the two ring bolts supplied by the factory see Fig 3 Check the ring bolts for hand tight seat Observe the maximum length and load bearing capacity of the attachment devices Two ring bolts already attached to the press module at the factory serve as attachment points 1 Fig 3 Example of typ...

Page 22: ...ress modules move the fork of the forklift under the pallet Carefully lift the load to check the center of gravity position Ensure a stable center of gravity position Make sure that the press module cannot move out of the intended position Only lift the press module as far off the floor as necessary for the transport Carefully set down the press module 6 1 3 Transport using cranes and similar lift...

Page 23: ...e for up to 6 months under the following conditions Do not store the press module outdoors but in a well ventilated room Avoid high light irradiation Protect the press module against humidity particularly ground humidity Store the press module on a shelf or on a pallet Observe the admissible load bearing capacities of your storage system Store the press module in the original packaging or comparab...

Page 24: ...on 7 1 Unpacking Open the press module packaging Check the press module for transport damage and completeness see chapter 4 Scope of delivery Dispose of the packaging in accordance with the currently applicable national provisions in your country 7 2 Installation conditions For installation always observe the environmental conditions specified in the IH04 data sheets see chapter 1 2 Required and a...

Page 25: ...aulic fluid jet using a cloth Do not disconnect pipe hose connections connections or components as long as the press module is pressurized Check the pressure at the provided measuring ports only after the hydraulic fluid jet has subsided CAUTION Insufficient assembly space Risk of injury Danger of crushing Danger of trapping your limbs Wear your personal protective equipment Make sure that connect...

Page 26: ...revent whip hazards Only pressurize the machine system after all hydraulic lines have been completely and properly mounted Make sure that on fittings and flanges all cap nuts pipes and hose lines and every combination of connection pieces couplings or connection points with hoses or pipes are checked for their operational safety by a person with appropriate knowledge and experience For the hydraul...

Page 27: ...ing from the connection points cutting ring connections must not be used Suitable connections are for example flange connections flared or sealing cone fittings Before installation care must be taken in accordance with DIN 3387 to ensure that the pipe ends to be connected are free of burrs undeformed and without threads Paint coatings and contamination must be removed The fitting can be reused aft...

Page 28: ...ows to hydraulically connect the press module 1 Depressurize the relevant system part 2 Establish all connections observing the hydraulic circuit diagrams of the machine 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 fit...

Page 29: ... provide for proper equipotential bonding Uncontrolled machine movements or malfunctions of the valves due to penetrating water and humidity Danger to life Risk of injury Risk of corrosion Use protection class IP65 plug in connectors Before assembly ensure that all seals and caps of the plug in connectors are tight and intact Uncontrolled machine movements caused by signal interference due to elec...

Page 30: ...ensure leak tightness between cable and cable gland Route the connection cable s in a strain relieved form The first mounting point must be within 15 cm of the cable entry Use finely stranded conductors only if they have pressed on insulated wire end ferrules Solenoid coils of valves such as WE and H WEH can be connected in a polarity independent way For the technical data such as mating connector...

Page 31: ...ssible pressure of the hydraulic components in the machine system cannot be exceeded Ensure that in your machine system the maximum admissible operating pressure is secured by means of pressure limitation equipment NOTICE Uncontrolled connection or disconnection of electrical component plug in connectors Damage to property Before installation works separate the press module from the mains or from ...

Page 32: ... When commissioning the press module on a machine system first of all commission the electronics that might exist and then the hydraulics When commissioning the electronics the hydraulics power unit valve etc must be switched off in order to prevent damage of the hydraulic components caused by incorrect wiring and malfunctions of the electronics Ensure a mechanical restraint function between the t...

Page 33: ...ctions of the hydraulic system see EN 289 par 5 3 7 operator responsibility Information on operating the press module can only be provided in connection with the machine system For this information please refer to the operating instructions of the overall machine system Pay attention to the various operating modes and their effects and or protective measures see EN ISO 16092 1 appendix E The press...

Page 34: ...air can be found in data sheets 07008 07300 07700 07800 and 07900 see chapter 1 2 Required and additional documentation 10 1 Cleaning and care NOTICE Damage to seals when using solvents or aggressive cleaning agents Damage to property Only ph neutral cleaning agents may be used for cleaning Malfunctions due to penetrating dirt and fluids Damage to property Do not use a high pressure washer for cle...

Page 35: ... and mounted valves are subject to a natural process of wear and aging Bosch Rexroth recommends replacement at appropriate time intervals The intervals are mainly determined by the operating conditions such as temperature and the cleanliness of the hydraulic fluid 10 3 Maintenance schedule The following maintenance work is required for the press module and must be included in the maintenance sched...

Page 36: ... seals of attached and mounted valves are subject to a natural process of wear and aging Bosch Rexroth recommends replacement at appropriate time intervals The intervals are mainly determined by the operating conditions such as temperature and the cleanliness of the hydraulic fluid 10 4 Maintenance Maintenance on the press module must be carried out in connection with the overall machine system Fo...

Page 37: ...schrexroth com 10 6 Spare parts NOTICE Malfunction of the press module machine due to the use of incorrect spare parts Damage to property Only use components listed in the product specific documentation parts list Only use new seals with the required media compatability As the sealing material may differ despite being of identical appearance the material number should be checked In case of questio...

Page 38: ...ked hydraulic fluid and dispose of it properly Have sufficiently dimensioned collecting containers residue free industrial wipes and hydraulic fluid binding materials ready in order to collect or bind leaking hydraulic fluid Only use valves or safety relevant components such as orifices listed in the product related parts list In determining the achievable category and performance level certain fa...

Page 39: ... press module is depressurized by connecting a suitable measuring device to the provided measuring points Please note that some pipeworks of the press module are still under pressure in the OFF operating mode Further information on this topic is included in the product specific documentation of the respective press module see chapter 1 2 Required and additional documentation Check whether the affe...

Page 40: ...e cylinder piston to a fall proof parking position switch off pumps and electric motors relieve the accumulators and secure the machine system against restarting Provide collecting containers that are large enough to accommodate the total hydraulic fluid volume at the press module including the pipework to the top oil tank Prepare disassembly of the press module as follows Connect the pressure gau...

Page 41: ...held securely by a mechanical restraint device Secure the press against restarting by selecting the OFF operating mode and then removing the key Never try to stop or seal the leakage or the hydraulic fluid jet using a cloth Do not disconnect line connections connections or components as long as the press module is pressurized Check the pressure at the provided measuring ports only after the hydrau...

Page 42: ...e the safety instructions applicable to transport and assembly see chapters 6 and 7 Ensure that the hydraulic system is depressurized Check whether the press module has cooled down sufficiently so that it can be disassembled in a risk free manner De energize the overall machine system Loosen and or separate the electric connectors and connections Disconnect the pipes hoses and collect any leaking ...

Page 43: ...ances or third party components when products are returned Hydraulic valves have to be drained before being returned The components have to be delivered free to the following address Bosch Rexroth AG Industrial Hydraulics Service Bürgermeister Dr Nebel Straße 8 97816 Lohr am Main Germany 13 3 Packaging Upon request reusable systems can be used for regular deliveries The materials for disposable pa...

Page 44: ...ing Due to the high metal content hydraulic products can mostly be recycled In order to achieve an ideal metal recovery disassembly into individual assemblies is required The metals contained in electric and electronic assemblies can be recovered by means of special separation procedures as well ...

Page 45: ...ltation with the manufacturer and by authorized trained and instructed personnel If you undertake any extensions to or modifications of the product marketed by Bosch Rexroth you are changing the condition as supplied Any certifications and statements made by Bosch Rexroth regarding this product will then become invalid In case of questions please contact Bosch Rexroth or your local Rexroth distrib...

Page 46: ...efore the error occurred first Try to determine any changes of the overall machine system in which the press module is integrated Were there any changes to the application conditions or area of application of the press module Has any maintenance work been performed recently Is there an inspection or maintenance record Have modifications e g refitting or repair works been performed on the overall m...

Page 47: ...heck whether the electrical plug in connectors are correctly and completely mounted Defective limit switch or no feedback information of position monitoring Replace the complete defective component Return the component for repair Have repair works of components with position monitoring performed by authorized personnel only Cable break Replace the connection cable Replace the connection cable Repl...

Page 48: ...mitted technical data of the respective press module can be found in the respective data sheet see chapter 1 2 Required and additional documentation The data sheet can be found on the Internet at www boschrexroth com mediadirectory For further information refer to the online product catalog at www boschrexroth com ...

Page 49: ... Active opto electronic guard AOS Device whose detection function is performed by emitting and receiving opto electronic components By interrupting the reception of the optical beam generated in the device the presence of an opaque object in the defined effective range is detected Contactless guard BWS Arrangement of devices and or components that work together to provide access protection or pres...

Page 50: ... area danger zone at the press Area between moving dies moving press slide moving die cushion and workpiece ejector Die cushion see pos Fig 4 pos 5 Auxiliary device for a lower die that accumulates and delivers or absorbs the required force for some forming operations with the press Gravity loaded axis Axes that can make unexpected dangerous movements due to gravity or stored energy as a result of...

Page 51: ...initiation of a movement e g by a two hand control device jog control or hand lever Monitoring Safety function that ensures that a safety measure is initiated if the function of a safety related valve can no longer be fully performed or if the process takes place under such changed conditions that hazards are created Muting Temporary automatic suppression of a safety function by safety related par...

Page 52: ...leasing the AOS following a double interruption e g for manual loading and unloading Operating mode OFF Operating mode in which the press is put out of operation Operating mode set up jog mode setting inch jog Operating mode for the purpose of installation or removal of dies adjustment of dies technical protective measures and other devices as well as cleaning inspection and maintenance where the ...

Page 53: ...rically connecting the press module 29 Emergency stop 51 Extension and modification 45 G Gravity loaded axis 50 Guarding Active opto electronic 49 Contactless 49 H Hydraulically connecting the press module 26 I Information of the machine manufacturer 15 Inspection 35 Installation conditions 24 Installing the press module 25 Intended use 8 J Jog mode 51 L Lower die 50 M Maintenance 36 Maintenance a...

Page 54: ...product and technology dependent 12 Signal word 6 Scope of delivery 18 Secure operational stop 51 Spare parts 37 Storage 20 Storing the press module 23 Symbols 7 T Technical data 48 Top dead centre 50 Transport 20 using cranes and similar lifting gear 22 using forklifts and similar floor conveyors 22 Transporting the press module 20 Troubleshooting 46 U Unpacking 24 Upper die punch 50 W Working cy...

Page 55: ...RE 63124 B Edition 08 2021 Bosch Rexroth AG Alphabetical index Press modules Type IH04 55 56 ...

Page 56: ...h AG Industrial Hydraulics Zum Eisengießer 1 97816 Lohr a Main Germany Tel 49 0 9352 40 30 20 my support boschrexroth com www boschrexroth com Subject to change without notice Printed in Germany RE 63124 B 08 2021 ...

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