Bosch Rexroth UPE2 General Operating Instructions Download

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Bosch Rexroth AG

Drive modules | RE 51150-B/07.11

Safety instructions

2.6 Product- and technology-related safety instructions

wARNING

Pressurized system!

Danger to life, risk of injury, severe injury when working at systems that have not

been stopped! Damage to property!

Ensure that the drive module is completely depressurized.

Do not disconnect lines, connections or components as long as the drive

module is under pressure.
Switch off all force-transmitting components and ports (electric, pneumatic,

hydraulic) according to the manufacturer's instructions and secure them

against restarting. If possible, remove the main fuse of the system.

High electrical voltage!

Danger to life, risk of injury caused by electric shock or severe injury!

Make sure the relevant system part is de-energized before assembling the

drive module or when connecting and disconnecting connectors.
Protect the system against being switched on.

leaking hydraulic fluid mist due to defective or improperly assem-

bled seals!

Risk of fire, risk of explosion, risk due to allergic reactions, environmental pollution!

Welding works may only be undertaken when the drive module is depressurized.

Keep open fire and sources of ignition away from the drive module.

CAUTION

leaking hydraulic fluid due to leakage of the drive module/the hydrau-

lic system!

Risk of burning! Risk of injury!

Switch the system off immediately (emergency stop switch).

Identify and remedy the cause of the leakage.

Never try to stop or seal the leak or the oil jet using a cloth.

Avoid direct contact with the leaking hydraulic fluid. It might be under

high pressure.
Carry out visual inspections for tightness of the drive module and the oil-

containing components on a regular basis.

Slip hazard due to oily surfaces!

Risk of injury!

Protect and mark the danger zone.

Use an oil binding agent in order to bind the leaked hydraulic fluid.

Remove and dispose of (see chapter 13 "Disposal") the contaminated oil

binding agent.
Wear your personal protective equipment like safety boots.

Summary of Contents for Rexroth UPE2

Page 1: ...Operating instructions RE 51150 B 07 11 Material no R901310980 Replaces English General operating instructions for clamping and drive modules and drive modules with and without control modules ...

Page 2: ...making own evalu ations and tests Our products are subject to a natural process of wear and aging This document as well as the data specifica tions 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 the phot...

Page 3: ...e modules 25 6 1 1 Preparing the drive module for transport 25 6 1 2 Manual transport 25 6 1 3 Transport using forklifts and similar floor conveyors 25 6 1 4 Transport by means of lifting gear and attachment points 26 6 1 5 Freight transport 28 6 2 Storing drive modules 28 7 Assembly 29 7 1 Unpacking 29 7 2 Drive module assembly 29 7 3 Hydraulically connecting the drive module 29 7 4 Connecting to...

Page 4: ... Hose lines 43 10 2 8 Piping 44 10 2 9 Heat exchanger UPE5 44 10 2 10External inspection of the tank 45 10 3 Repair 46 10 4 Spare and wear parts 46 11 Decommissioning 47 11 1 Preparing for decommissioning 47 11 2 Decommissioning the drive module 47 12 Disassembly and exchange 48 12 1 Preparing disassembly 48 12 2 Disassembling the drive module 48 13 Disposal 49 14 Extension and conversion 50 15 Tr...

Page 5: ...red to customer specifications For this reason you should keep the general and product specific documenta f f tion to hand when reading these instructions see Chapter 4 Scope of delivery You should observe the documentation for the complete machine f f You should also observe the documentation pertaining to the other compo f f nents assemblies and partly completed machinery which form part of the ...

Page 6: ...and source of danger Consequences in case of non compliance Measures for the prevention of dangers f f Enumeration f f Warning sign Draws attention to the hazard Signal word Identifies the degree of hazard Type and source of danger Specifies the type and source of the hazard Consequences Describes the consequences of non compliance Precautions Specifies how the hazard can be prevented Risk classes...

Page 7: ...tion is not observed the product cannot be used and or operated optimally f f Individual self dependent step 1 2 3 Numbered instruction The numbers indicate that the steps must be carried out one after the other 1 3 3 Abbreviations The following abbreviations are used in this documentation Abbreviations Table 4 Abbreviation Meaning REXXXXX B Rexroth document in English language RXXXXXX B Rexroth d...

Page 8: ... movements It is therefore essential for the manufacturer of the complete machine to have undertaken an independent risk assessment Furthermore the manufacturer must on this basis have prepared operating instructions for the complete machine 2 2 Intended use The drive module constitutes partly completed machinery in terms of EC Ma chinery Directive 2006 42 EC In terms of the EC Machinery Directive...

Page 9: ...nts in the overall concept must be completely understood 2 5 General safety instructions Observe the valid regulations on accident prevention and for environmental protection Observe the safety regulations and provisions of the country where the product is implemented used Exclusively use Rexroth products in good technical order and condition Observe all notes on the product Persons who assemble o...

Page 10: ... f Leaking hydraulic fluid mist due to defective or improperly assem bled seals Risk of fire risk of explosion risk due to allergic reactions environmental pollution Welding works may only be undertaken when the drive module is depressurized f f Keep open fire and sources of ignition away from the drive module f f CAUTION Leaking hydraulic fluid due to leakage of the drive module the hydrau lic sy...

Page 11: ...ke the appropriate measures to ensure that no hazard to a person s life or health or to property may occur Also observe the superordinate operating instructions for the ma chine or system Obligations of the machine manufacturer 2 8 In order to ensure safety when handling the drive module the manufacturer of the machine must Select the safest installation position for the drive module possible in o...

Page 12: ... and use of the operating instructions and the legal regulations Intended use and operation of the Bosch Rexroth product Observation of the instructions from the factory security office as well as the operator s operating instructions How to behave in case of emergency Bosch Rexroth offers measures supporting the training in specific fields You can find an overview of the training contents on the ...

Page 13: ...wear or malfunctions Make sure that all connections hydraulic lines and attachment parts f f e g measuring instruments are clean and free of chips For removing lubricants or any other heavy pollution use industrial residue f f free wipes Before commissioning ensure that all hydraulic and mechanical connections f f are connected During filling filter the hydraulic fluid using a suitable filter syst...

Page 14: ...fluid Environmental pollution and pollution of the ground water Use an oil binding agent in order to bind the leaked hydraulic fluid f f When filling and draining the hydraulic fluid always put a drain tray under the f f drive module Observe the information in the safety data sheet of the hydraulic fluid and the f f system manufacturer s specifications ...

Page 15: ...ocumentation These documents are listed in the following table Scope of delivery documents Table 5 Document Drive module Assembly Product specific documentation Technical specification x x Hydraulic diagram x Catalog sheet if applicable Component list to the hydraulic diagram x Catalog sheet if applicable Assembly drawing x Catalog sheet if applicable EC declaration of incorporation x General docu...

Page 16: ...diagram Function s and logic mode of operation of the product Component list to the hydraulic diagram Assembly drawing Structural design dimensions connections etc Drive modules according to these operating instructions at least consist of Electric motor and pump Tank Oil level display Apart from that drive modules may comprise Hydraulic control Accumulator Pump pressure limiting device Additional...

Page 17: ...product Drive module UPE2 Fig 1 Tank with electric motor and pump 1 Filling plug 2 Oil level display 3 Name plate 4 Terminal box 5 Control connection surface 6 Through holes for fastening screws 7 Oil drain screw 8 Explanation of the function See table 6 1 2 3 4 5 6 7 8 UPE2 ...

Page 18: ...or accepting the hydraulic fluid 2 Filling plug Filling of the tank with hydraulic fluid 3 Oil level display Hydraulic fluid level monitoring 4 Name plate Name plate for the unambiguous identification of the drive module 5 Terminal box Connection electric motor as well as connec tion temperature switch optional 6 Control connection surface Connection surface for attaching the filling plug 7 Throug...

Page 19: ...formation on this product Interfaces 5 3 Hydraulic connections 5 3 1 Hydraulic connections drive module UPE2 Fig 3 Pump connection P for con 1 trol modules Tank port T for control modules 2 Oil drain screw 3 Explanation of the function See table 7 1 2 3 UPE2 ...

Page 20: ...ion the control mod ules are supplied with hydraulic fluid 2 Tank port T Via the tank port the hydraulic fluid of the control modules is led back into the tank 3 Oil drain screw Tank draining 4 Cooler connection K1 for leakage oil Control pump leakage oil connection 5 Tank port T1 Oil leakage in the tank under minimum oil level 6 Tank port T2 T3 T4 T5 External actuator tank oil connection 7 Suctio...

Page 21: ...oth AG 21 56 Information on this product Electrical connections 5 3 2 Electrical connections drive module UPE2 Fig 5 Electric motor 1 Temperature switch 2 Oil level display with level switch 3 Explanation of the function See table 8 UPE2 2 3 1 ...

Page 22: ...tric motor 1 Temperature switch 2 Oil level display with level switch 3 Electrical connections drive modules Table 8 No Element Function 1 Electric motor Oil immersed motor or electric motor for pump drive 2 Temperature switch Hydraulic fluid monitoring 3 Oil level display with level switch Hydraulic fluid level monitoring UPE5 2 3 1 ...

Page 23: ...neral documentation Delivery note and accompanying documents Drive module UPE2 Fig 7 Manufacturer 1 Technical data of the electric motor 2 Date of manufacture 3 Personal stamp of the examiner 4 Personal stamp of the fitter 5 Area works number 6 Terminal allocation 7 Material number 8 Material short text 9 Designation of origin 10 Circuit diagram symbol 11 Technical data of the pump 12 UPE2 ...

Page 24: ...8 Manufacturer 1 Technical data of the electric motor 2 Date of manufacture 3 Personal stamp of the examiner 4 Personal stamp of the fitter 5 Area works number 6 Connection sizes 7 Material number 8 Material short text 9 Designation of origin 10 Circuit diagram symbol 11 Technical data of the pump 12 UPE5 ...

Page 25: ...pressure on the gas side to a value of 2 bar 200 kPa Bosch Rexroth always delivers drive modules without hydraulic fluid Any deviations from this rule are described explicitly in the product specific documentation From the factory inspection there may however still be oil residues in the product Manual transport 6 1 2 CAUTION Hazard due to overload and or unsuitable gesture during lifting and tran...

Page 26: ...y means of lifting gear and attachment points 6 1 4 The drive module can be transported by means of lifting gear in connection with attachment devices e g lifting strap or chain Make sure that the lifting capacity of the lifting gear and the attachment devic f f es is sufficiently dimensioned in order to safely bear the drive module s weight The weights of the drive modules are contained in table ...

Page 27: ... a crane hook f f Make sure that the lifting strap or chain cannot damage attachment parts dur f f ing lifting Lift the drive module slowly and carefully taking into consideration the stable f f center of gravity location in order to avoid oscillations of the drive module Ensure that the control modules of the drive module do not come into contact f f with the lifting gear during transport Transpo...

Page 28: ...he drive module do not come into f f contact with the attachment devices during transport Storing drive modules 6 2 For storing the drive module you have to comply with the following environmen tal conditions Table 9 Storage conditions Denomination Area Temperature range 10 25 C Relative humidity no condensation Max 65 UV protection 100 Condensation None Additional ozone formation close to the sto...

Page 29: ...odule so that its longitudinal and transverse axes are horizontal 4 Securely fix the drive module at the mounting positions specified in the gen 5 eral documentation Hydraulically connecting the drive module 7 3 Remove the plugs and flange covers colored plastic and replace them by pressure resistant fittings or flanges You should observe the manufacturer s installation instructions for the screw ...

Page 30: ...rive module to the machine The drive modules must be grounded The earthing line and the lines for the potential equalization must have the mini mum cross section as per VDE regulations and a yellow green sheath or labeling Before connecting the cables you should earth the device that is to be con f f nected and provide for potential equalization via a common equalizing bar Laying the power supply ...

Page 31: ...that the line system is in good work safe condition f f Open the taps in the cooling water line if present f f Get the data sheets of the components to be assembled according to the f f parts list ready Keep the suitable tool ready f f Compare the pressure adjustment of the type tested pressure relief valve with f f the maximum admissible operating pressure of the accumulator if available The pres...

Page 32: ...g equipment arrow Fig 11 Accumulator 8 1 4 If the drive modules includes accumulators the instructions applicable at the place of installation are to be complied with before commissioning as well as dur ing operation Operating Instructions are supplied with each accumulator You should ensure that these documents are kept together with the accumula f f tor Experts will need these for subsequent ins...

Page 33: ...ny water present f f and remove via the drain cock Recommendation Experience has shown that the cleanliness class required for operation of the machine is already exceeded in the case of new hydraulic fluids in the original container If you wish to ensure that the cleanliness class is acceptable use a special filter unit for filling the drive module if necessary or use a filter station with fine f...

Page 34: ...n stalling the drive module into the machine and or after installing with the hydraulic system it must be ensured that the minimum requirements are met with respect to the cleanliness class of the components Hydraulic systems in general indus trial applications require a cleanliness class of 20 18 15 according to ISO 4406 whereas hydraulic systems with servo valves or high response valves of highe...

Page 35: ...ess level has been attained or continued Only make operating pressure settings at the pressure valves intended for that purpose Never change the setting of sealed valves or valves with a fixed factory setting After completing the flushing process care should be taken to ensure that the operating settings of the drive module are restored that any flushing connections are dismantled and connection l...

Page 36: ...s side The tightness of the hydraulic components and the line system Perform switch on procedures with increased caution f f Bleed the hydraulic system f f Observe the information in the operating instructions of the machine manufacturer f f f f Contact Bosch Rexroth for the re commissioning after a standstill of more than 3 months f f In order to re commission the drive module proceed as describe...

Page 37: ...e manufacturer f f Leakage at joints due to seal failure caused by excessive temperatures Risk of injury Ensure that with drive modules without temperature switch the maximum f f operating temperature remains within the temperature range prescribed in the relevant data sheet NOTICE Transmission of vibration from the machine by switching the hydraulic valves at the control Unforeseeable reactions r...

Page 38: ...odule Bosch Rexroth recommends checking the hydraulic system and the drive module regularly Continuously monitor noises vibrations and temperatures f f After some operating time check the hydraulic fluid in the tank for bubble or f f foam formation at the surface Changes in operating speeds temperatures noise increase or power consump tion are an indication of wear or damage at the system or the d...

Page 39: ...the application of external force Maintenance documentation 10 1 It is recommended that the results of the inspections and the derived measures required be documented So that considering functionality and economy the service intervals can be adjusted to the actual operating conditions As they offer the possibility of early fault recognition thanks to comparative evaluation preventive maintenance A...

Page 40: ... fluid entry e g water in the case of internal leaks of the oil water cooler Optionally the drive module may be equipped with an electric fluid level indicator The switching points can be seen from the technical specification and the circuit diagram Measures to be taken if the maximum filling level is exceeded Approximately determine the expansion by temperature increase f f delta V thermal expans...

Page 41: ...e filter element must be replaced at the end of the shift at the latest In addition the monitoring equipment may be electrical for evaluation at con trol level For the switching point please refer to the technical specification and the f f circuit diagram You should be wary if the filter clogging indicator still does not indicate that a replacement is necessary after several inspection intervals O...

Page 42: ...e Do not use reconditioned oil recovered oil f f In case of an oil change drain the hydraulic fluid completely in this connec f f tion see also Chapter 11 1 Preparing for decommissioning In this connection ensure complete draining of the lines and actuators f f If necessary carry out ventilation measures f f Fill the hydraulic system and subsequently bleed it as with the initial filling f f Hydrau...

Page 43: ... assemblies consist of an elastic part hose and fittings mounted on both sides Hose lines are components requiring permanent monitoring Danger Risk of breaking hose lines due to overload or aging UPE5 Danger to life risk of injury Replace the hose lines after 6 years at the latest or if damage is visible f f Replace the hose lines if one of the following is determined during the inspection f f Dam...

Page 44: ...at welded seams you must determine f f and remedy the cause Afterwards you must replace the components con cerned or repair them in a professional manner If there are signs of an application of external force you must determine and f f remedy the cause Afterwards the component and also adjacent pressur ized components are to be checked for damage and assessed with respect to further reliable use I...

Page 45: ...component and also adjacent components are to be checked for damage and assessed with respect to further reliable use If necessary the components are to be replaced or repaired in a profes sional manner If there are signs of an application of external force on the tank an internal inspection of the tank should be undertaken In case of crack formation at welded seams you must determine and remedy f...

Page 46: ...uired resistance to media f f As the sealing material may differ despite being of identical appearance the f f material number should be checked Order spare parts in writing f f Please send your spare parts order to the Bosch Rexroth service next to you or f f directly to the headquarters see List of addresses in chapter 17 Appendix When ordering spare parts please indicate the following informati...

Page 47: ... sure that there are no hazards caused by adjacent machines f f Do not allow uninvolved persons to remain in the area concerned f f Lower the load or provide for safe foundation f f Decommissioning the drive module 11 2 Switch off the electric power and secure the system against re activation f f short circuit bridge supply side Switch off the hydraulic pressure supply and secure it against re act...

Page 48: ...plete the follow ing steps Carry out the decommissioning as described in chapter 11 of these operating f f instructions Do not allow uninvolved persons to remain in the area concerned f f Disassembling the drive module 12 2 When disassembling you should perform the work steps described in Chap f f ter 7 Assembly but in reverse order f f Despite prior draining hydraulic fluid will still seep out of...

Page 49: ...ispose of the drive module in accordance with the currently applicable na f f tional regulations in your country Disassemble the drive module into its individual components in order to re f f cycle them Dispose of hydraulic fluid residues according to the respective safety data f f sheets valid for these hydraulic fluids Separate f f Cast iron Steel Non ferrous metal Seals Plastic Electronic compo...

Page 50: ...ng this product will then become invalid This means the following for drive modules Drive modules are partly completed machinery in terms of EC Machinery Directive 2006 42 EC Together with the general and product specific docu mentation you have received a declaration of incorporation for these prod ucts In the case of extension to or conversion of the drive module this declaration will become inv...

Page 51: ...rmine any changes of the overall system in which the drive module f f is integrated Were there any changes to the drive module s operating conditions or operat ing range Were there any changes e g retrofitting or repair works on the entire system machine system electrics control or on the drive module If so What were they Was the drive module or machine used as intended How did the fault become ap...

Page 52: ...the drive module if necessary use oil of a lower viscos ity class Admissible hydraulic fluids see data sheet Oil foams proportion of air too great Check and remedy the cause of the ingress of air Impact of defect B Insufficient power torque pressure in the drives Table 11 Fault Possible causes Remedy 1 Pressure valves Operating pressure setting too low Control of the setting according to the speci...

Page 53: ...in the system inlet pressure too low or deposits in the heat exchanger Check whether the coolants air water comply with the requirements of the technical specification 5 Other Increased reduction in efficiency due to changed conditions also wear if applicable Perform maintenance work replace components if necessary Impact of defect E Polluted hydraulic fluid Table 14 Fault Possible causes Remedy 1...

Page 54: ... pump UPE5 Clockwise Installation position UPE2 Vertical UPE5 Depending on design horizontal vertical wall mounting Mode of operation UPE2 All modes of operations in which the oil temperature remains below 80 C UPE5 S1 continuous operation Protection class ccording to VDE 0530 EN 60034 UPE2 IP54 with drive module completely mounted UPE5 IP55 with drive module completely mounted Weight Table 16 Typ...

Page 55: ...RE 51150 B 07 11 Drive modules Bosch Rexroth AG 55 56 Appendix Appendix 17 List of addresses 17 1 Please refer to www boschrexroth com for addresses of foreign subsidiaries ...

Page 56: ...ydraulics Zum Eisengießer 1 97816 Lohr am Main Germany Phone 49 0 93 52 18 0 Fax 49 0 93 52 18 23 58 documentation boschrexroth de www boschrexroth de Subject to change without notice Printed in Germany RE 51150 B 07 11 ...

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