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Bosch Rexroth A4CSG 30 Series Manual

Axial piston variable pump
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RE 92105-01-X-B2/2019.08.06
Replaces: 08.2017
Axial piston variable pump
A4CSG Series 30
for explosive areas
II 2G Ex h IIC T4-T1 Gb X and
II 3G Ex h IIC T4-T1 Gc X
Information on explosion protection
▶ Application per Directive 2014/34/EU (ATEX)
▶ Gas: II 2G Ex h IIC T4-T1 Gb X according
to DIN EN ISO 80079-36 :2016,
DIN EN ISO 80079-37:2016
▶ Gas: II 3G Ex h IIC T4-T1 Gc X according
to DIN EN ISO 80079-36 :2016,
DIN EN ISO 80079-37:2016
Features of the ATEX version
The ATEX version is an advanced development of the
A4CSG for compliance with Directive 2014/34/EU (ATEX).
External features distinguishing it from the standard pump
as per data sheet 92105 are the ground terminal, the
Ex marking and the CE marking on the name plate.
For ATEX category II 2G Ex h IIC T4-T1 Gb X, an additional
temperature sensor for monitoring the operation data
is supplied.
Temperature classes per DIN EN ISO 80079-36
Depending on the two temperature classes, T3 and T4,
observe the maximum permissible temperatures
(see "Hydraulic fluid" and "Operating data monitoring -
X parameters").
▶ Sizes 250, 355, 500
▶ Nominal pressure 350 bar
▶ Maximum pressure 400 bar
▶ Closed circuit
Contents
RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG
Part II of instruction manual
in accordance with ATEX
Directive (2014/34/EU)
data sheet
2
4
5
6
7
7
8
9
11
12
13
14
36
38
44
46
47
50
51

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Summary of Contents for Bosch Rexroth A4CSG 30 Series

  • Page 1: Table Of Contents

    Integrated boost pump and Depending on the two temperature classes, T3 and T4, valve technology (version F..) observe the maximum permissible temperatures Filtration types (see "Hydraulic fluid" and "Operating data monitoring – Installation instructions X parameters"). Project planning notes Safety instructions RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 2: Type Code

    Please contact us. starting on page 21. Compared to the standard pump, the technical data is restricted in terms of temperature, case pressure and bearing flushing/ installation position. -S2145 only up to 3 bar case pressure for temperature class T4 See DIN EN ISO 80079-36, 6.4.2.1 Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 3 Please observe the project planning notes on page 50! All attachment pumps must comply with the application-specific For information on storing and preserving axial piston units, ATEX classification. see Data Sheet 90312. For Equipment Category II 2G Ex h IIC T4-T1 Gb X not available RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 4: Hydraulic Fluids

    θ = -25 °C to +90 °C θ = -25 °C to +80 °C ▼ Selection diagram Maximum permissible viscosity on cold start 1000 Optimum operating viscosity range v Optimum efficiency Minimum permissible viscosity for short-term operation 80 90 Minimum permissible temperature on cold start Temperature θ [ °C] Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...

  • Page 5: Operating Data Monitoring - X Parameters

    ▶ Reservoir level monitoring is also required. When the minimum boost pressure of 8 bar is not Operating conditions for T3 and T4 reached, switch off the system immediately. Size ● ● ● ● ● ● 500...-S2145 ● ● Just up to maximum 3 bar case pressure RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 6: Leakage Temperature Monitoring For Atex Category Ii 2G Ex H Iic T4-T1 Gb

    Notice – evaluation electronics for temperature monitoring The necessary evaluation electronics are not included in the scope of delivery. The sensor must be operated via an explosion-proof current circuit. The protection class must be at least that of the sensor (see “Information on explosion protection” on page 1). Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...

  • Page 7: Filtration Of The Hydraulic Fluid

    U must be turned in to the end stop. Permissible differential pressure on shaft seal (housing pressure to ambient pressure), not to exceed p A drain line to the L max. reservoir is required. Only with double shaft seal, see type code position 15 RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 8: Working Pressure Range

    + ... + t Notice ∆t Working pressure range applies when using hydraulic fluids based on mineral oils. ∆p All assembled parts must meet the ATEX classification for the application in question. Time t See also "Monitoring the operational data" on page 5 Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...

  • Page 9: Technical Data

    The data are valid for values between the minimum required and maximum permissible rotational speed. Valid for external excitation (e. g. diesel engine 2 to 8 times rotary frequency; cardan shaft twice the rotary frequency). The limit value is only valid for a single pump. The load capacity of the connection parts must be considered. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 10 D max ▼ Distribution of torques Pump 1 Pump 2 Torque at 1st Pump Torque at 2nd Pump Torque at 3rd Pump Input torque < E max Through-drive torque < D max Efficiency not considered For drive shafts free of radial force Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...

  • Page 11: Hd - Hydraulic Control, Pilot-Pressure Related

    As a result, the flow in the axial piston unit will no longer respond correctly to the operator's specifications. Check whether the application on your machine requires additional safety measures to bring the driven consumer to a safe position (immediate stop). If necessary, make sure these are appropriately implemented. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 12: Ep - Electrohydraulic Control With Proportional Solenoids

    As a result, the flow in the axial piston ATEX classification. unit will no longer respond correctly to the operator's specifications. Check whether the application on your machine requires additional safety measures to bring the driven consumer to a safe position (immediate stop). If necessary, make sure these are appropriately implemented. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...

  • Page 13: Solenoid Technical Data

    IEC 60079-0: 2011 IEC 60079-18: 2009 EC type examination certificate IBExU 13 ATEX 1040 X IECEx certificate of conformity IECEx IBE 13.0017 X IP rating per IEC/EN 60529 Minimum IP67 Appliance protection class according to DIN VDE 0580 EC declaration of conformity DC013315-001 DC013315-001 DC013316-001 RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 14: Circuit Diagrams

    Boost port (external) Measuring boost pressure Accumulator port Measuring flushing pressure R(L) Fluid filling, air bleeding Fluid drain Pressure relief valve relief port Flushing port (bearing flushing) Measured value transducer, temperature Pilot pressure port for pressure controller Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 15 Boost port (external) Measuring boost pressure Accumulator port Measuring flushing pressure R(L) Fluid filling, air bleeding Fluid drain Pressure relief valve relief port Flushing port (bearing flushing) Measured value transducer, temperature Pilot pressure port for pressure controller RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 16 Filter, supply Filter, return Boost port (external) Measuring boost pressure Accumulator port Measuring flushing pressure R(L) Fluid filling, air bleeding Fluid drain Pressure relief valve relief port Flushing port (bearing flushing) Pilot pressure port for pressure controller Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 17 Filter, supply Filter, return Boost port (external) Measuring boost pressure Accumulator port Measuring flushing pressure R(L) Fluid filling, air bleeding Fluid drain Pressure relief valve relief port Flushing port (bearing flushing) Pilot pressure port for pressure controller RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 18: Dimensions, Size 250To

    DIN 46228-A1.5-7 Side B deep M12x16 143.5 143.5 ▼ View X 36.5 Flange 224, 4-hole, Solenoid A based on ISO 3019-2 (metric) R(L) Ground connection Solenoid B Connection table, see page 20 10 mm shorter for version with single shaft seal Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 19 B E2 K4 A Pressure relief valve B 10.3 192.5 Flushing pressure relief valve to flange surface ▼ View Y ▼ View U 50.8 36.5 HAGGLUNDS www.hagglunds.com to flange surface to flange surface to flange surface to flange surface RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 20 Depending on the installation position, T, K or R(L) must fittings. be connected (see also from page 47) Only dimensions according to SAE J518, metric fastening thread O = Must be connected (comes plugged) is a deviation from the standard. X = Plugged (in normal operation) Temperature sensor must be installed. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 21 Side B M E3 M ABP M12x16 143.5 143.5 ▼ View X 36.5 Flange 224, 4-hole, based on ISO 3019-2 Solenoid A (metric) R(L) Ground connection Solenoid B Connection table, see page 23 10 mm shorter for version with single shaft seal RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 22 Pressure relief valve, initial control pressure Pressure relief valve B 10.3 192.5 Flushing pressure relief valve to flange surface ▼ View Y ▼ View U 50.8 36.5 M K4 to flange surface to flange surface to flange surface to flange surface Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 23 Depending on the application, momentary pressure peaks can occur. be connected (see also from page 47) Keep this in mind when selecting measuring devices and fittings. O = Must be connected (comes plugged) Only dimensions according to SAE J518, metric fastening thread is a X = Plugged (in normal operation) deviation from the standard. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 24 M E3 M ABP deep M12x16 143.5 143.5 ▼ View X 36.5 Flange 224, 4-hole Based on ISO 3019-2 Solenoid A (metric) R(L) Ground connection Solenoid B Connection table, see page 26 10 mm shorter for version with single shaft seal Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 25 Initial control pressure 4 K A Pressure relief valve B 10.3 Flushing pressure 192.5 relief valve to flange surface ▼ View Y ▼ View U 50.8 36.5 M K4 to flange surface to flange surface to flange surface to flange surface RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 26 (see also from page 47) fittings. O = Must be connected (comes plugged) Only dimensions according to SAE J518, metric fastening thread X = Plugged (in normal operation) is a deviation from the standard. Temperature sensor must be installed. The countersink may be deeper than specified in the standard. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 27 Side B M E3 M ABP M12x16 143.5 143.5 ▼ View X 36.5 Flange 224, 4-hole Based on ISO 3019-2 Solenoid A (metric) R(L) Ground Solenoid B connection Connection table, see page 29 10 mm shorter for version with single shaft seal RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 28 Pressure relief valve, initial control pressure Pressure relief valve B 10.3 Flushing pressure 192.5 relief valve to flange surface ▼ View Y 50.8 ▼ View U 36.5 M K4 to flange surface to flange surface to flange surface to flange surface Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 29 Depending on the application, momentary pressure peaks can occur. be connected (see also from page 47) Keep this in mind when selecting measuring devices and fittings. O = Must be connected (comes plugged) Only dimensions according to SAE J518, metric fastening thread is a X = Plugged (in normal operation) deviation from the standard. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 30 Ground connection End-splice DIN 46228-A1,5-7 R(L) 10000 ▼ View X 44.5 Solenoid A Ground connection Flange, 315, 4-hole, Pressure control based on ISO 3019-2 Side A (metric) Pressure control Side B Ground connection Solenoid B 10000 Connection table, see page 32 Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 31 Pressure relief valve A 41 50 Pressure relief valve, initial control pressure Flushing pressure relief valve 10.3 Pressure relief valve B 192.5 ▼ View U ▼ View Y 44.5 50.8 to flange surface to flange surface to flange surface RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 32 (see also from page 47) and fittings. O = Must be connected (comes plugged) Only dimensions according to SAE J518, metric fastening thread X = Plugged (in normal operation) is a deviation from the standard. Temperature sensor must be installed. The countersink may be deeper than specified in the standard. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 33 Ground connection End-splice DIN 46228-A1,5-7 R(L) ▼ View X 44.5 Solenoid A Ground connection Flange 224, 4-hole Pressure control according to ISO Side A 3019-2 (metric) Pressure control side B Ground connection Solenoid B 10000 Connection table, see page 35 RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 34 Pressure relief valve Initial control pressure 10.3 Pressure relief valve B Flushing pressure 192.5 relief valve to flange surface ▼ View Y ▼ View U 50.8 44.5 to flange surface to flange surface to flange surface to flange surface Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 35 Depending on the application, momentary pressure peaks can occur. be connected (see also from page 47) Keep this in mind when selecting measuring devices and fittings. O = Must be connected (comes plugged) Only dimensions according to SAE J518, metric fastening thread is a X = Plugged (in normal operation) deviation from the standard. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 36: Combination Pumps

    15600 Permissible mass moment of inertia 1560 with dynamic mass acceleration 10g ≙ 98.1 m/sec Weight Distance from center of gravity To air bleed the stroking chamber, use the highest port on the control (see data sheet of the controller) Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 37 152-4 (D) 1 3/4 in (44-4) F/17 – – 140 (S)/31 According to DIN 5480 (e.g. W32) or according to SAE J744 (e.g. 3/4 in) 2 = 2-hole, 4 = 4-hole On request If a through drive for an A10V(S)O with R-shaft is desired, please contact us. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 38: Dimensions, Through Drive

    M20 x 2.5; 24 deep 63 63 O-ring O-ring 95.7 shown without cover shown without cover 10.3 10.3 Splined shaft Splined shaft (to mounting flange) (to mounting flange) ø115 ø115 Thread according to DIN 13, see instruction manual for details on tightening torques Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 39 ▼ F/35 (to mounting flange) (to mounting flange) 12.5 M16; 22 deep 12.5 M20; 30 deep Thread according to DIN 13, see instruction manual for details 4 mounting bolts and O-ring seal are included in the scope on tightening torques of delivery. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 40 M20; 30 deep 12.5 94.5 Thread according to DIN 13, see instruction manual for details 8 mounting bolts and O-ring seal are included in the scope on tightening torques of delivery. 4 mounting bolts and O-ring seal are included in the scope of delivery. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 41 M16; 24 deep 18.5 43.5 19.9 ▼ F/B6 (to mounting flange) 10.4 M16; 24 deep Thread according to DIN 13, see instruction manual for details 2 mounting bolts and O-ring seal are included in the scope on tightening torques of delivery. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 42 43.5 M12; 15 deep 18.9 19.5 40.5 M10; 15 deep 48.4 M12; 15 deep 19.4 Thread according to DIN 13, see instruction manual for details 2 mounting bolts and O-ring seal are included in the scope of delivery. on tightening torques Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 43 10.4 M16; 24 deep 10.3 Thread according to DIN 13, see instruction manual for details 4 mounting bolts and O-ring seal are included in the scope of delivery. on tightening torques. 2 mounting bolts and O-ring seal are included in the scope of delivery. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 44: Integrated Boost Pump And Valve Technology (Version F

    NG500 quantity of system case drain fluid, it may be necessary to increase the boost volume with a larger or additional boost pump. NG250 Integrated boost pump (Pos. 9) Standard size 1000 1500 2000 2200 Rotational speed [rpm] Larger boost pumps available on request Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 45 Fluid filling + air bleeding Return flow (drain port) R(L) Bearing flushing Boost pressure supply Measuring boost pressure Accumulator port Measuring boost pressure Measuring stroking chamber pressure Measuring stroking chamber pressure Pilot pressure, remote control pressure controller RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 46: Filtration Types

    M33 × 2; 18 deep DIN 3852 M33 × 2; 18 deep DIN 3852 [bar] State Ports max abs Filter, supply Filter, return For components and ports, see page 30 All attachment pumps must match the ATEX classification for the application in question. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...

  • Page 47: Installation Instructions

    When designing the reservoir, ensure that there is an adequate distance between the suction line and the drain line. This minimizes oil turbulence and carries out degassing, which prevents the heated hydraulic fluid from being sucked directly back in again. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 48 F. For version K, observe the external boost pump specification. Notice ▶ With installation position 5, only operate the axial piston unit with bearing flushing. ▶ Port F is part of the external piping and must be provided on the customer side to make filling and air bleeding easier. Bosch Rexroth AG, RE 92105-01-X-B2/2019.08.06...
  • Page 49 Baffle (baffle plate) t min Minimum required immersion depth (200 mm) t min Minimum required distance to reservoir bottom (100 mm) Maximum permissible suction height 800 mm for s max version F. For version K, observe the external boost pump specification. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...

  • Page 50: Project Planning Notes

    ▶ Not all versions of the product are approved for use in a safety function according to ISO 13849. Please consult the proper contact at Bosch Rexroth if you require reliability parameters (e.g. MTTF ) for functional safety. ▶ Depending on the type of control used, electromagnetic effects can be produced when using solenoids.

  • Page 51: Safety Instructions

    The machine/system manufacturer must test whether remedial measures are needed on the machine for the application concerned in order to bring the driven consumer into a safe position (e.g. safe stop) and ensure any measures are appropriately implemented. RE 92105-01-X-B2/2019.08.06, Bosch Rexroth AG...
  • Page 52 A4CSG Series 30 | Axial piston variable pump Axial piston variable pump | A4CSG Project planning notes Bosch Rexroth AG © Bosch Rexroth AG 2019. All rights reserved, also regarding any disposal, An den Kelterwiesen 14 exploitation, reproduction, editing, distribution, as well as in the event 72160 Horb a.N. of applications for industrial property rights. The data specified within only Germany serves to describe the product.

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