Operating instructions

Pressure reducing station R417000844 R417000845R417000888

Imprint:

The copyright of this users manual remains the property of Bosch-Rexroth AG.

Included are instructions and technical drawings, which may not be reproduced or copied either in part of whole, nor may they be used for evaluation or distributed for competition pur-poses.

The diagrams and drawings used in this manual are for guidelines only and are not to be used for the actual design.

This edition supersedes all previous ones. No part of this edition may be reproduced whithout our prior permission.

Order Number: 883 890 035 3 BDL 001 AC

Table of contents

27

Safety information 28 Explanation of symbols 28

GB Occupational safety 29 Design and mode of operation 30General 30 Block diagram 32 Versions 33

Startup 34Ports and Installation, Assembly position, 34

Maintenance and care 35 General 35 Replacing the sealing elements, dismantling 36Dismantling the filters and the drain valves 36Dismantling the pressure switch 38and the adjusting screw Dismantling the pressure control valves 38Dismantling the three/two-way valve 40Replacing the sealing elements, assembly 42Setup and Tests 43 Spare parts package 44

Storage and transportation 45 General 45

Technical specifications 46 General 46 Circuit diagram 46 Dimensional drawing 47

After sales service and adresses 48Any questions? 48

883 890 035 3 BDL 001 AC (10/06)

Safety information

28

Explanationof symbols

Danger!This symbol is to be found with allinformation and warnings in theseoperating instructions regarding worksafety, where there is potential dangerto humans. Take notice of such warnings and actwith particular caution in these cases.

Warning!

Warning!

This symbol is to be found in theseoperating conditions wherever it is necessary to ensure that guidelines,regulations and warnings are adheredto and that the work processes are carried out correctly, without damageto or destruction of the servo-actuator.

This way up!This symbol is found wherevercomponents have to be transported,stored or mounted in a particularposition. (to DIN 30 600)

Grease!

FettGrease

This symbol is to be found wherevercomponents, areas etc. need to belubricated.

Secure by glue!This symbol is marking parts which must be secured by means of a liquid adhesive (according to DIN 30 600).

883 890 035 3 BDL 001 AC (10/06)

Safety information

29

Occupationalsafety

WarningDo only pressurise the pressure-reducing station, if it has beenmounted properly.

Do not handle the pressure-reducing station, if it is pressurised. Always cut off the air supply before starting work.

Technical State The pressure-reducing station has been designed according to thelatest state of the technology and safety standards for operation.

Proper UseThe pressure-reducing station has the following purpose:Reduction of a high inlet pressure to a low outlet pressure.

The ambient conditions as well as the operating pressure rangespecified in the technical data have to be observed. The compressedair supplied must be clean, dry and free of lubricant.

Air quality:

Quality class acc. to :PNEUROP-

recommendation6611 / 1984

ISO 8573-1

Solid matters 4 7

Oil rate 3 3

Pressure dew point 2 3

Applications other than those stated are regarded as not appropriate.Improper use is at the customer's risk. The manufacturer is not liablefor any resulting damage.

This device may cause danger if it is used improperly, underinappropriate conditions or by unqualified personnel.

Using the device appropriately does, of course, also mean observingthe assembly, dismantling and maintenance instructions.

GuaranteeThe pressure-reducing station must by maintained and repaired byauthorised, skilled personnel only.

The user must only operate the pressure-reducing station in perfect condition.

The user is obliged to report any changes of the device's condition thatmight reduce its safety.

Unauthorised modifications and changes that might reduce the safetyof the pressure-reducing station are not permitted.

Before commissioning please read the operating instructionscarefully.

883 890 035 3 BDL 001 AC (10/06)

Design and mode of operation

30

General

PurposeThe pressure-reducing station has the following purposes:

x Filtering the pressurized air and condensing

x Reduction of a high inlet pressure to a low outlet pressure

x Monitoring of the reduces outlet pressure via pressure gauge andsafety valve

x Ventilation of the compressed air tab A.

DesignThe pressure-reducing station consists of a housing that contains thefollowing components (fig. 1) :

compressed air filter with drain valve (1), pressure control valves (2),safety valve (3), pressure gauge (4), 3/2-way valve, operated electro-magnetically (5) and pressure switch (6) with testing tab (7).

Mode of operation The pressurized air entering at point P (pmax = 30 bar) flows throughthe compressed air filter (1) and is cleaned from solid impurities. The resulting condensate is collected in the lower part of the housing andmay be drained via the drain valve.

The cleaned, pressurized air then reaches the pressure control valve(2). Here the reduction from the inlet pressure to a lower outlet pressure (3 bar...8,5 bar) takes place. The outlet pressure set at the pressure control valve is indicated at the pressure gauge (4). The safety valve (3) has to limit the operating pressure in the pressure-reducing station to a maximum of 8,5 bar in order to prevent damagesto the connected devices.

The compressed air continues to flow from the pressure control valve (2) to the electro-magnetically operated 3/2-way valve (5). This valve can supply the tab A with compressed air. In addition to tab A tabP1 also furnishes a constant compressed air supply.

The pressure switch (6) is used for monitoring of the reduced outlet pressure. In case a lower threshold limit of the pressure value has been exceeded, an electrical contact is closed.The compressed air tab 14 can be used to supply compressed air tothe testing tab (7) for the pressure switch, thus ensuring that the function of the pressure switch (6) can be continuously monitoredduring operations. In order to enable this feature, the adjusting screwof the testing tab has to be turned into the housing until it stops.

883 890 035 3 BDL 001 AC (10/06)

Design and mode of operation

31

General

If the compressed air supply at tab P is interrupted, the pressure-reducing station is vented by force; thus ensuring that no pressure is present at any of the subsequent devices.

(cf. block diagram on page 32 and circuit diagram on page 46)

VersionsFig. 2a - 2c show three versions of the pressure reducing station,which basically differ in the arrangement of the pressure switch and the pressure gauge.

883 890 035 3 BDL 001 AC (10/06)

Design and mode of operation

Block-diagram

PP

1

A

14

1

2

3

4

567

fig. 1

32883 890 035 3 BDL 001 AC (10/06)

Design and mode of operation

33

Versions

fig. 2a : R417000888 (replacement for 335 320 200 0)

pressure gauge

drain valve

3/2-way-valve

safety valve pressure switch

fig. 2b : R417000845 (replacement for 335 320 201 0)

pressure gauge

safety valve

drain valve

pressure switch

3/2-way-valve

883 890 035 3 BDL 001 AC (10/06)

Startup

34

Versions

Ports and Installation

Assemblyposition

fig. 2c : R417000844 (replacement for 335 320 202 0)

Ports and Installation The pressure-reducing station is fixed with 3 screws M10. The boringpattern can be taken from the dimensional drawing.

Pneumatic connections are materialised by traded ports M14x1.5.

Assembly position For assembly purposes it has to be taken into account that the drain valve points downwards.

Warning!When disassembled dirt, humidity or foreign matter must not enter the compressed air ports. For this reason the ports must be closed bymeans of suitable transportation protecting plugs. The disassembled pressure-reducing station must be protected fromenvironmental influences. Before assembly the transportationprotecting plugs must be removed. In addition the device must be visually inspected for damages of any kind.

Warning!

drain valve

3/2-way-valve

safety valve pressure switch

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

35

General

Maintenance intervals In order to guarantee a safe operation of the pressure-reducingstation, all sealing elements must be replaced after 3 years at thelatest provided that the required compressed-air quality and the permissible ambient conditions are observed. We recommend to return the pressure reducing station to Bosch Rexroth AG for repairs. For the replacement of sealing elements at ownresponsibility a spare part kit 335 320 003 2 is available.

The following maintenance and care instructions have to be adheredto:

Drain valve The filters should be drained daily using the drain valve. In order to do so, the handles of the drain valve should be slightly moved sideways.

Warning!Warning!If the valves are under pressure, the condensate is very powerfullyejected. Do not move the handles with your hands but use suitable tools to move the handles sideways.

Cleaning of the filter cartridge The filter cartridges have to be cleaned regularly according to the stateof contamination of the compressed air. For cleaning purposescleaner's naphtha or dissolvents can be used. Dry the filter cartridgebefore returning it to its position. Follow fig.3 for the removal and reinsertion of the cartridges.

Danger!Conduct all works on the pressure-reducing station only in an un-pressurized state.

Warning! Warning!Check the seals at the fastening screw. Ensure that the cartridge is not installed at an angle.

Replacing the filter cartridges Extremely dirty filter cartridges should be replaced by new ones.The required parts are contained in the spare parts package335 320 003 2.

FettGrease

Greasing the sealing elements The sealing elements of the pressure-reducing station have to begreased lightly using the lubricant contained in the repair set beforeassembly, except if they are subject to special maintenance and careinstructions.

Before assembly, all sealing seats, faces etc. have to be cleaned.

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

36

DismantlingReplacing the sealing elements, dismantling

The following section describes the dismantling and assembly of a pressure-reducing station for the replacement of the sealing elements.

All elements necessary for a complete scheduled overhaul arecontained in the spare parts package 335 320 003 2.

In case of such an overhaul, the following instructions for the dismantling/mounting have to be adhered to.

Warning! Warning!Conduct all works in a de-pressurized state. Shut off the compressed air supply and vent the device ! Interrupt the electric power supply.

Dismantling the filters and the drain valves (fig. 3)

x Loosen fastening screw T1 and remove sealing ring 1, filter 2 andO-ring 3

x Remove valve screw T2 and sealing ring 4

x Remove circlip 7 and spring 6 as well as valve 5 from the valvescrew T2.

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

37

fig.3

C

BA

1

2

3

T1MA = 150Nm

Y

X

C B A

T25T26

T11

267

view X

view Y

5

T2MA = 60Nm

6

4

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

38

Dismantling

Dismantling the pressure switch (fig. 4a) (Version R417000888 , R417000844 , 3353202000 and 3353202020)

x Disassemble pressure switch T3. Loosen screw T4 (2x)

x Remove O-ring 36

Dismantling the pressure switch (fig. 4b) (Version R417000845 and 3353202010)

x Disassemble pressure switch T3. Loosen screw T4 (2x)

x Disassemble adapter T12 and screw T24 (2x)

x Remove O-ring 11 and 36

Dismantling the pressure control valves (fig. 5)

x Loosen grub screw T7 and remove cap T8 from the housing

x Remove spring T9 and piston 35 with O-ring 14

x Disassemble circlip 15 and pull valve 16 together with valve nut17, bushing 18, valve ring 19, O-ring 21 and O-ring 34 from the drill hole. Remove spring 20

x Dismantle circlips 22, 24 and filters 23, 25

x Remove banjo bolt T11 from the housing and remove piston cup 26(cf. fig. 3).

Dismantling the adjusting screw (fig. 4a)

x Disassemble circlip 12 and remove washer T5

x Remove adjusting screw T6 from the housing. Remove O-rings 8,9 and 10

x Remove ventilation 13.

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

fig.4a

39

13

89

10

36

fig.4b

T5

12

T6

T3

T411

T12

T2436T4T3fig.5

T8

T7

T9

35

14

24

25

X

23

22

9.8

37

17

16

15

18

34

20

21

13.6

+0

.2

YB-B

19Take care of

mounting position ! view X

view Y

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

40

Dismantling Dismantling the 3/2-way valve (fig. 6)

x Loosen screw T25 and remove holding plate T26 (fig. 3)

x Dismantle servo valve 33. In order to do so, remove ventilationT13, the coil T14 and loosen the screw T15 (2x)

x Remove gasket 27

x Loosen screw T16 (2x) and remove the base plate T17

Warning! Warning!compression spring T18 is pre-stressed

x Disassemble the following parts: compression spring T18,bushing T19, piston T20, sleeve T21, ram T22, washer T23 (6x),washers 32, spacer T24 (2x), sealing ring 28 (4x) as well asgrooved ring 29

x Disassemble circlips 24, 30 and filters 25, 31.

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

T18

T19

32

T23T24

28

X

28

T20

T21

T22

32

T23T24

28

29

Y

28

X

Y

33

T15

T16

T17

25

24

30

31

C-C

D D

T13 1.2 NmM =A+0.2

T14

D-D27

fig.6

41883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

42

AssemblyReplacing the sealing elements, assembly Reassemble the device in reverse sequence.Take care not to damage the sealing elements during assembling.

FettGrease

All sealing elements must prior to assembling be slightly lubricatedwith the grease from the spare parts kit. Before this all sealing surfaces are to be cleaned.

Assembly of the filter and the drain valve (fig. 3)

x Replace sealing ring1, filter 2 and O-ring 3. Tightening torque forfastening screw T1: MA = 150 Nm

x Replace sealing ring 4, valve 5, spring 6 and circlip 7. Tighteningtorque for valve screw T2: MA = 60 Nm

x Replace piston cup 26.

Assembly of the pressure switch and the adjusting screw(fig. 4)

x Replace O-rings 8, 9, 10, 11, 36, circlip 12 and ventilation 13.

Assembly of pressure control valve (fig. 5)

x Replace circlip 15, valve 16, valve nut 17, bushing 18, valve ring19, spring 20, O-rings 14, 21, 34 and piston 35.

Warning! Warning!Keep clearance 13.6 - 0.2 mm for valve nut 17. For checking useadjusting sleeve 37.Secure valve nut 17 with substance for locking screws (e. g. Loctite 241).

Warning!Warning!Ensure correct assembly position of valve ring 19!

x Replace circlips 22, 24 and filters 23, 25.

883 890 035 3 BDL 001 AC (10/06)

+

Maintenance and care

43

Assembly

Setup and Test

Assembly of the 3/2-way valve (fig. 6)

x Replace gasket 27, sealing ring 28 (4x) and grooved ring 29

x Replace circlips 24, 30 and filters 25, 31.

Warning! Warning!Bushing T19 and sleeve T21 must overhang the upper housing edge

by 0.4 r0.1mm. Attach washers 32 accordingly.

x Replace servo valve 33

Warning! Warning!In case of pressure reducing stations with holding plate T26 (newversion) during assembly the srew T25 must be fixed by a screwsecuring means (e.g. Loctite 241).

In case of pressure reducing stations without holding plate T26 (oldversion) the exhaust T13 must be tightened with a torque of MA = 1.2+0.2 Nm and a screw securing means (e.g. Loctite 241) must beapplied.

Secure screw T15 (2x) and screw T16 (2x) with substance forlocking screws (e. g. Loctite 241).

Setup and Tests of the pressure-reducing station After the dismantling/mounting of the pressure-reducing station, it is required to set up the operating pressure of the pressure controlvalves again. In order to do so, the grub screw T7 has to be loosenedand the cap T8 has to be screwed from the housing with the exception of the last five turns. Set tab P to a pressure of 30 bar. By turning the cap T8 the operatingpressure at the pressure control valve can be adjusted, then tightenthe grub screw T7.

Warning! Warning!Turn cap T8 only in pressureless state.

Check the 3/2-way valve for correct performance by working it. Finally the complete pressure-reducing station has to be tested fortightness.

883 890 035 3 BDL 001 AC (10/06)

Maintenance and care

44

Spare parts package

335 320 003 2

Spare parts package: Order number 335 320 003 2

Item Description Dimension Qty.

1 sealing ring 36 x 42 x 2 1

2 filter 1

3 O-ring 23,3 x 2,4 1

4 sealing ring 22 x 27 x 1,5 1

5 valve 1

6 conical spring 0,8 x 12,7 x 26,5 1

7 circlip 15 x 1 1

8 O-ring 6 x 1,5 1

9 O-ring 5 x 1,2 1

10 O-ring 4 x 1,2 1

11 O-ring 6,75 x 1,78 1

12 circlip 20 x 1 1

13 ventilation M14 x 1,5 1

14 O-ring 32,9 x 3,5 1

15 circlip 14 x 1 1

16 valve 1

17 valve nut 1

18 bushing 8 x 9 x 4 1

19 valve ring 1

20 conical spring 1 x 11,2 x 18,1 1

21 O-ring 5,28 x 1,78 1

22 circlip 20 x 1,5 1

23 filter 20 x 2,3 1

24 circlip 8,3 x 0,5 2

25 filter 8 x 2 2

26 piston cup 3 x 8 x 4 1

27 gasket 18 x 3 1

28 sealing ring 4

29 grooved ring 12,8 x 21,2 x 4 1

30 circlip 30 x 1,2 1

31 filter 30 x 2 1

32 washer 13 x 0,2 6

33 servo valve 1

34 O-ring 10 x 1,3 1

35 piston 1

36 O-ring 6 x 2 1

37 adjusting sleeve 1

38 lubricant 20g

883 890 035 3 BDL 001 AC (10/06)

Storage and transportation

45

General

During storage and transportation the pressure-reducing station must in principle be protected against mechanical damage and weatherinfluences.

Contacts with aggressive media must be avoided.

Compressed air ports must be closed in a way to prevent entry of dirt, humidity and foreign matter.

The ambient temperature during storage and transportation must

neither drop below -35qC nor exceed +80qC.

Storage

Warning! Warning!Consider that sealing elements are subjected to ageing also duringstorage. The storage period must be taken into account for deter-mining the replacement intervals appropriately.

Transportation

Danger!In principle the provisions for the prevention of accidents must beobserved. Above all the device must during transportation be securedagainst getting out of place resp. falling down.

883 890 035 3 BDL 001 AC (10/06)

Technical specifications

General

Technical Data

Permissible medium compressed air

inlet pressure max. 30 bar

outlet pressure min. 3 bar / max. 8,5 bar

pressure reducing valve adjusted to 7,5 bar

safety valve adjusted to 8,5 bar

pressure switch adjusted to 6,0 bar , decreasing

threaded tabs M14 x 1,5

thermal application range 273 K 343 K

Circuit diagram

fig. 7

P

A

P1

14

1

2

3

4

5

6

7

46883 890 035 3 BDL 001 AC (10/06)

Technical specifications

Dimensional drawing / Version R417000888

fig. 8

threaded tabs: M14 x 1.5; 12 deep

47883 890 035 3 BDL 001 AC (10/06)

After sales service and adresses

48

anyQuestions?

Are there any questions left? If anything is still not clear after reading these operating instructions,please let us know. Your suggestions for improvements are alwayswelcome.

If you require any further information, please contact the sales staff in our Marine Technique Division directly or the address below.

Bosch Rexroth AG

The Drive & Control Company

Marine Technique

Ulmerstrae 4

D 30880 Laatzen

Tel.: +49 (0) 511 2136 251

Fax.: +49 (0) 511 2136 165

e-mail: marinesales@boschrexroth.de

Internet: http://www.boschrexroth.de