Related Manuals for Bosch rexroth DBD 1X/ E Series
Summary of Contents for Bosch rexroth DBD 1X/ E Series
- Page 1 Pressure relief valve, direct operated (Safety valve according to Pressure Equipment Directive 2014/68/EU) Type DBD...1X/..E Replaces 25402-B/03.20 Operating instructions English RE 25402-B/10.21 Mat. no. R901557680...
- Page 2 IT: La messa in servizio di questo prodotto può essere eseguita solo se si dispone del presente manuale d‘uso in una lingua ufficiale della UE conosciuta e se ne è stato compreso il contenuto In caso contrario rivolgersi al referente Bosch Rexroth o al punto di assistenza competente.
- Page 3 NL: U mag het product pas in bedrijf stellen, als deze bedieningshandleiding voor u beschikbaar is in een voor u begrijpelijke, officiële taal van de EU en als u de inhoud daarvan begrepen heeft. Is dit niet het geval, neem dan a.u.b. contact op met uw Bosch Rexroth contactpersoon of de servicepartner.
- Page 4 © 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 the figure shown.
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Page 5: Table Of Contents
Operation with counter pressure in the discharge line Maintenance and repair 10.1 Cleaning and care 10.2 Inspection and maintenance 10.3 Repair 10.4 Spare parts Disassembly and replacement Disposal 12.1 Environmental protection 12.2 Return to Bosch Rexroth AG RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... - Page 6 6/56 12.3 Packaging 12.4 Materials used 12.5 Recycling Extension and modification Troubleshooting 14.1 How to proceed for troubleshooting 14.2 List of addresses Alphabetical index Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
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Page 7: About This Documentation
The described hazard avoidance measures must be observed. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... - Page 8 Meaning If this information is not observed, the product cannot be used and/or operated optimally. Individual, independent action Numbered instruction: The numbers indicate that the actions must be carried out one after the other. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
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Page 9: Safety Instructions
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. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... -
Page 10: Intended Use
Changes at the product are only admissible within the scope specified in these operating instructions. Any safeguards fitted by Bosch Rexroth AG have to be present, properly installed and fully functional, unless this is not appropriate for setup or maintenance operation. -
Page 11: Qualification Of Personnel
• In particular, completely understanding the correlations regarding the safety equipment and • Having knowledge of the function and set-up of hydraulic components. Bosch Rexroth offers measures supporting the training in specific fields. Please find an overview of the training contents on the Internet at: http://www.boschrexroth.de/didactic... -
Page 12: General Safety Instructions
• Do not commission the product until you can be sure that the end product (for example a machine or system) where the Rexroth product is installed complies with the country-specific provisions, safety regulations and standards of application. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 13: Product-Specific Safety Instructions
Do not use the safety valve in areas with open fire and only at a sufficient distance to hot heat sources. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... - Page 14 Only use the safety valve within the environmental and fluid temperatures intended for that purpose. In case of leakage, immediately exchange damaged seals or the safety valve. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
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Page 15: Personal Protective Equipment
2.8 Obligations of the machine end-user The operator of the Bosch Rexroth safety valve is responsible that the safety valve is only used according to the intended use as defined in these operating instructions. -
Page 16: General Information On Damage To Property And Damage To The Product
Leaking hydraulic fluid leads to environmental pollution. Immediately remedy possible leakage. Dispose of the hydraulic fluid in accordance with the currently applicable national regulations in your country. Wear! Wear may lead to malfunctions. Carry out the prescribed maintenance works. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 17: Scope Of Delivery
Check the scope of delivery for possible transport damage, see section 6 "Transport and storage". In case of complaints, please contact Bosch Rexroth AG, see section 14.2 "List of addresses". Valve mounting screws are not included in the scope of delivery; they can, however, be ordered separately. -
Page 18: Product Identification
/1 – x. Alternatively, the CE mark may also be embossed at the valve body. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... - Page 19 The related setting certificate will then apply to all identical safety valves of this production order and to the customer’s or production order number specified in the setting certificate, the total number x of the valves will be added in the form /1 – x. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
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Page 20: Component Marking
Table 8: Limitations of use Valve size Response pressure p in bar maximum flow q in l/min Vmax 60...315 320...500 NG6, 10, 20, 30 see characteristic curves and see characteristic curves and component marking component marking Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 21: Transport And Storage
Transport and storage 21/56 6 Transport and storage 6.1 Transporting the product Bosch Rexroth hydraulic valves are high-quality products. In order to prevent damage at the safety valve, transport the safety valves in the original packaging or with equivalent transport protection. CAUTION... -
Page 22: Storing The Safety Valve
• Use textile attachment devices according to DIN EN 1492-2. More information regarding the transport is available from Bosch Rexroth. More information regarding the transport using chain hoists is also available in the data sheet 07600-B, chapter 6 "Transport and storage". -
Page 23: Assembly
Components cannot be properly mounted or might be damaged. Make sure that the assembly space is sufficient. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... -
Page 24: Unpacking
7.4 Necessary tools In order to assemble the safety valve, you need standard tools only. Apart from that, you need a manual torque wrench to tighten the valve mounting screws. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 25: Accessories
Assembly 25/56 7.5 Accessories The following accessories are recommended. They are not included in the scope of delivery and can be ordered separately from Bosch Rexroth: Table 9: Valve mounting screws for subplate mounting Valve type + size Component marking... -
Page 26: Prior To Assembly
If the material number of the safety valve does not match the number in the order confirmation, contact the Rexroth service for clarification; for the address see chapter 14.2 "List of addresses". Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... - Page 27 -remove the clamping sleeve at the rotary knob for safety valves of size 6...20. -release the countersunk screw at the hand wheel for safety valves from size 30. Rotary knob or hand wheel must be re-attached after completed assembly. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
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Page 28: Assembly Of Screw-In Cartridge Valves
Steel is to be assumed as valve material in this case. Secure screw-in cartridge valves against unauthorized removal from the mounting cavity by wire or seal. A bore is already provided for this in the valve hexagon (except DBD4). Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 29: Assembly Of Valves For Subplate Mounting
Tighten them crosswise using a suitable manual torque wrench. For the tightening torques, please refer to the table further down. Please note that the tightening torques may change if other screw types are used. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... -
Page 30: Assembly Of Valves With Threaded Connection
G 1 1/2 according to EN ISO 228 Part 1 Tightening torque , related to 60 Nm 130 Nm 380 Nm 600 Nm the max. operating pressure Friction coefficient µ = 0.09 to 0.14 Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 31: Additional P Port (Only With Response Pressure Up To 400 Bar)
EN ISO 228 Part 1 Tightening torque , related to the 30 Nm 60 Nm 135 Nm 560 Nm max. operating pressure Friction coefficient µ = 0.09 to 0.14 RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... -
Page 32: Commissioning
• The released operating media and limitations of operation for your safety valve are hydraulic fluid contained in "Data sheet 25402 and/or 25710". • Bosch Rexroth offers the suitable seal designs for the hydraulic fluid used. Bleeding the hydraulic Bleeding of the safety valve is usually not necessary. However, Bosch Rexroth system recommends bleeding the entire hydraulic system. -
Page 33: Operation
DBDH..1X/..E", screw in the adjustment spindle again as far as possible but do not tighten the lock nut yet after unloading the spring. Switch on the system and wait until the system pressure has built up. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... - Page 34 P and which you have deactivated or removed before to the normal operating state. As an alternative to the procedure described above, the safety valve may also be removed and set to the desired lower response pressure on a test stand. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
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Page 35: Operation With Counter Pressure In The Discharge Line
Area I Interpolation area I, for valves DBD.4K1X/..E with response pressure =60...315 bar and maximum flow q =10 l/min Vmax Area II Interpolation area II, for valves DBD.4K1X/..E with response pressure =320...500 bar and maximum flow q =17 l/min Vmax RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... - Page 36 Value to be marked at the axis referred to as p : 1/10 ·150 bar = 15 bar, Read off the maximum admissible counter pressure p of approx. 8 bar from the diagram (see arrows, dashed characteristic curve). Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
- Page 37 Mark the system flow to be secured at the axis referred to as q Vmax Read off the maximum admissible counter pressure for this value using the line at the axis referred to as pT drawn before. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
- Page 38 Value to be marked at the axis referred to as p : 1/10 · 80 bar = 8 bar, Read off the maximum admissible counter pressure of approx. 3 bar from the diagram (see arrows, dashed characteristic curve). Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
- Page 39 Regarding the procedure for interpolation refer to the explanatory notes on the preceding pages. Response pressure in bar Maximum admissible counter pressure in the discharge line (port T) in bar Maximum flow in l/min Vmax Area (cross-hatched, gray) Interpolation areas RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
- Page 40 T of the safety valve dependent on the flow q for safety Vmax valves DBD.20.1X/..E with different response pressures p Intermediate values can be determined by means of interpolation. Regarding the procedure for interpolation refer to the explanatory notes on the preceding pages. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
- Page 41 Vmax valves DBD.30.1X/..E with different response pressures p . Intermediate values can be determined by means of interpolation. Regarding the procedure for interpolation refer to the explanatory notes on the preceding pages. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
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Page 42: Maintenance And Repair
Do not use linting fabric for cleaning. Ensure that no cleaning agents are able to penetrate the hydraulic system. Flush the hydraulic system if necessary. Replace the fluid filter or the hydraulic fluid. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... - Page 43 After unloading, the rotating spindle must be brought back into the initial position by means o the rotary knob. This is the only way to guarantee that the valve will still work with the response pressure pre-set by Bosch Rexroth.
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Page 44: Repair
Only repair measures listed in chap. 10 "Maintenance and repair" are admissible. Only qualified personnel (see chap. 2.4 "Qualification of personnel" may repair the safety valve. The sealing and/or the safety cap must not be removed. The point with locking paint must not be removed. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 45: Spare Parts
Component 1038 850, 390 marking R961000879 R961000882 R961000885 R961000888 R961000891 R961000880 R961000883 R961000886 R961000889 R961000892 R961000884 R961000887 R961000890 R961000893 The spare parts are available from the address specified in chap. 14.2 "List of addresses". RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG... -
Page 46: Disassembly And Replacement
Close the connection and/or installation bore or threaded connections of the valve installation surface in order to avoid contamination of the system. In case of new installation and/or exchange of the safety valve, the following steps are analog to chapter 7 "Assembly". Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... -
Page 47: Disposal
The materials for disposable packaging are mostly cardboard, wood, and polystyrene. They can be recycled without any problems. Due to ecological reasons, disposable packaging should not be used for returning products to Bosch Rexroth. The screw-in cartridge valve is delivered in a plastic packaging. -
Page 48: Recycling
– Was the safety valve or machine used as intended? – How did the fault become apparent? Try to get a clear idea of the cause of the error. If necessary, ask the actual (machine) operator. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... - Page 49 Equipment Directive The viscosity of the hydraulic Check whether a suitable hydraulic 2014/68/EU, fluid is outside the valve fluid can be used in the system and Appendix I, chap. 7.3). specification. exchange the hydraulic fluid. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
- Page 50 Order a new seal kit according to the spare part list and tighten the screw- in cartridge valve using the specified torque, see table 10. Seal the screw-in cartridge valve again at the housing. Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21...
- Page 51 Following faults due to contamination, it is moreover essential to check the quality of the hydraulic fluid and to improve it, if necessary, by suitable measures such as flushing or the additional installation of filters. RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
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Page 52: List Of Addresses
In your request, please specify the production number, the date of manufacture and the type designation of your safety valve. All these specifications are indicated on the name plate of the safety valve, see chap. "Product identification". Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... - Page 53 53/56 RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
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Page 54: Alphabetical Index
Functional safety Troubleshooting ▶ H ▶ U Hydraulic accumulator Unloading ▶ I Identification Installation conditions Installation position Intended use ▶ L Lifting gear Limitations of use ▶ M Maintenance interval ▶ O Order confirmation Bosch Rexroth AG, DBD...1X/..E, RE 25402-B/10.21... - Page 55 Alphabetical index 55/56 RE 25402-B/10.21, DBD...1X/..E, Bosch Rexroth AG...
- Page 56 Bosch Rexroth AG Zum Eisengießer 1 97816 Lohr am Main Germany Tel: +49 (0) 9352/40 30 20 my.support@boschrexroth.de www.boschrexroth.com Subject to change without notice Printed in Germany RE 25402-B/10.21...