Pressure Relief Valve, Pilot-Operated
Pressure Relief Valve, Pilot-Operated
Pressure Relief Valve, Pilot-Operated
pilot-operated
(Safety valve according to Pressure Equipment Directive 2014/68/EU)
Type DB(W)...5X/...E
Replaces --/--
Operating instructions English
RE25802-B/07.16 Mat. no. R901441995
The data specified serves to describe the
product. If there is also information on the
use, it is only to be regarded as application
examples and proposals. Catalog information
does not constitute warranted properties.
The information given does not release the
user from the obligation of own judgment and
verification. Our products are subject to a
natural process of wear and aging.
Inhalt
1 About this documentation 5
1.1 Validity of the documentation 5
1.2 Required and amending documentation 5
1.3 Representation of information 5
2 Safety instructions 7
2.1 General information on this chapter 7
2.2 Intended use 7
2.3 Improper use 8
2.4 Qualification of personnel 9
2.5 General safety instructions 9
2.6 Product-specific safety instructions 10
2.7 Personal protective equipment 12
2.8 Obligations of the machine end-user 12
3 General information on damage to property and damage to product 13
4 Scope of delivery 14
5 Product information 14
5.1 Product identification 15
5.2 Component marking 18
5.3 Limitations of use 18
6 Transport and storage 19
6.1 Transporting the product 19
6.2 Storing the safety valve 20
7 Assembly 21
7.1 Unpacking 22
7.2 Installation conditions 22
7.3 Painting the valve housing 22
7.4 Necessary tools 22
7.5 Accessories 23
7.6 Prior to assembly 23
7.7 Assembly of valves for subplate mounting 25
7.8 Assembly of valves with threaded connection 26
7.9 Additional M port 27
7.10 Connecting the power supply (only with type DBW...5X/..E) 28
8 Commissioning 29
9 Operation 30
9.1 General information on the operation 31
9.2 Setting the valve to a low response pressure 31
9.3 Operation with counter pressure in the discharge line 32
9.4 Operating the optional manual override at the directional valve 36
10 Maintenance and repair 37
10.1 Cleaning and care 37
10.2 Inspection and maintenance 37
10.3 Repair 40
10.4 Spare parts 41
11 Disassembly and replacement 42
12 Disposal 43
4/52
About this documentation 5/52
6/52 About this documentation
Signal word
Type and source of danger!
Consequences in case of non-compliance
ff Hazard avoidance measures
ff <Enumeration>
1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase the
comprehensibility of the documentation.
Symbol Meaning
If this information is not observed, the product cannot be used and/or
operated optimally.
Safety instructions 7/52
1.3.3 Designations
The following designations are used in this documentation:
Table 4: Designations
Designation Meaning
AD2000 Rules regarding the application and implementation of the Pressure
Equipment Directive
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Table 5: Abbreviations
Abbreviation Meaning
EN European Standard
DIN Deutsche Industrienorm (German Industry Standard)
ISO International Organization for Standardization
DB Pressure relief function
EU European Union
VDMA German Machinery and Plant Manufacturing Association
2 Safety instructions
ff Read this documentation completely and thoroughly before working with the
product.
ff Keep this documentation in a location where it is accessible to all users at all
times.
ff Always include the required documentation when you pass the product on to
third parties.
8/52 Safety instructions
Please consult us for information on the use of the product with other hydraulic
fluids.
The safety valve may only be operated in a technically unobjectionable condition
and it may only be stored, operated and maintained according to the technical data,
operating and environmental conditions indicated in these operating instructions.
Particularly the limit values specified in "Data sheet 25802" must not be exceeded.
The valve may only be used with other connection, application and performance
data than those defined in these operating instructions with the written approval by
Bosch Rexroth AG.
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.
Their position must not be changed; they must not be circumvented or made
ineffective.
Safety instructions 9/52
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
10/52 Safety instructions
WARNING
Pressurized system parts and leaking hydraulic fluid!
When working at hydraulic systems with stored pressure energy (accumulator
or cylinders working under gravity), valves may even be pressurized after the
pressure supply has been switched off. During assembly and disassembly works,
the safety valve or parts may fly around and cause personal injuries and/or damage
to property. There is moreover the danger of serious injury caused by a leaking
hydraulic fluid jet.
ff Ensure before working at the safety valve that the hydraulic system is
depressurized and the electrical control de-energized.
ff Completely unload the pressure at machines and systems before working at
valves.
Faulty mounting!
Mounting of the safety valve with valve mounting screws of reduced stability or
insufficient mounting at blocks and plates with insufficient stability may cause the
safety valve to become loose and fall down. Consequently, hydraulic fluid may leak
and lead to personal injuries and/or damage to property. Safety valves with high
weight may bruise or kill persons. Special care must be taken with safety valves
with suspended installation.
ff Completely assemble the safety valve according to the assembly specifications
by means of suitable assembly aids.
ff Only assemble the safety valve at valve installation surfaces suitable for the
weight of the valves.
ff Comply with tightening torques and screw stabilities.
Safety instructions 11/52
WARNING
High weight and sharp edges of the safety valve!
The described safety valve may be very heavy. In case of improper handling, it may
fall down and cause serious injuries and/or crush injuries as the safety valve may
e. g. be sharp-edged, heavy, oily, loose or bulky.
ff If necessary, transport the safety valve to the intended places using suitable
lifting gear.
ff Provide for a stable position during transport to the place of installation.
ff Wear personal protective equipment while transporting and assembling the
safety valve.
ff Comply with the national laws and regulations regarding occupational health
and safety for the transport.
Hot surface!
Risk of burning!
ff Provide for a suitable touch guard.
ff During operation, only touch the safety valve with heat-protective gloves. Allow
the safety valve to cool down to room temperature before touching it directly
with your hands during maintenance works.
CAUTION
Contaminated hydraulic fluid!
Contamination in the hydraulic fluid may cause functional failures of the safety
valve. In the worst case, this may result in unexpected system movements and thus
constitute a risk of injury for persons.
ff Ensure adequate hydraulic fluid cleanliness according to the cleanliness classes
of the safety valve over the entire operating range.
Contact with salt water leads to increased corrosion at the safety valve. Thus,
mounting screws and plug screws as well as movable components may be
chemically corroded and damaged. So take suitable corrosion protection
measures.
12/52 Safety instructions
If leakage at the valve can lead to water or soil contamination, the valve must be put
into a suitable collecting pan.
General information on damage to property and damage to product 13/52
NOTICE
Inadmissible mechanical movement!
Impact or shock forces on the safety valve may damage or even destroy it.
ff Never use the safety valve as handle or step. Do not place/put any objects on
top of it.
Wear!
Wear may lead to malfunctions.
ff Carry out the prescribed maintenance works.
14/52 Scope of delivery
4 Scope of delivery
The scope of delivery includes:
Accessories such as valve mounting screws are not included in the scope of delivery;
they can, however, be ordered separately. (see chap. 7.5 "Accessories").
5 Product information
For information on the performance and product description please refer to
"Data sheet 25802" of your valve.
Product information 15/52
2 6
1 95
4
3
12
9
14
18 8 19
10 11 5
14 CE mark 3)
18 Component marking
19 Reference number of the testing authority
95 Rexroth QR code
1)
Consecutively assigned code number for valves from a production order.
2)
Consecutively assigned number. This number is identical with the valve no. in the related
certificate regarding the setting of safety valves (setting certificate) and thus allows for the
unambiguous assignment of the valve to this setting certificate. If one production order comprises
several identical safety valves, the same number may be assigned to all valves from this production
order. The related setting certificate will then apply to all identical 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.
3)
Alternatively, the CE mark may also be embossed at the valve body.
16/52 Product information
14 CE mark 3)
18 Component marking
19 Reference number of the testing authority
95 Rexroth QR code
1)
Consecutively assigned code number for valves from a production order.
2)
Consecutively assigned number. This number is identical with the valve no. in the related
certificate regarding the setting of safety valves (setting certificate) and thus allows for the
unambiguous assignment of the valve to this setting certificate. If one production order comprises
several identical safety valves, the same number may be assigned to all valves from this production
order. The related setting certificate will then apply to all identical 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.
3)
Alternatively, the CE mark may also be embossed at the valve body.
Product information 17/52
14 CE mark 3)
18 Component marking
19 Reference number of the testing authority
95 Rexroth QR code
1)
Consecutively assigned code number for valves from a production order.
2)
Consecutively assigned number. This number is identical with the valve no. in the related
certificate regarding the setting of safety valves (setting certificate) and thus allows for the
unambiguous assignment of the valve to this setting certificate. If one production order comprises
several identical safety valves, the same number may be assigned to all valves from this production
order. The related setting certificate will then apply to all identical 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.
3)
Alternatively, the CE mark may also be embossed at the valve body.
18/52 Product information
The maximum admissible flow stated in the component marking must not be
exceeded.
It applies to:
•• External pilot oil return (=Y in the type code) without counter pressure in the
discharge line Y, admissible counter pressure in the discharge line (port T)
< 15 bar
•• Internal pilot oil return (= no code in the type code). The maximum admissible flow
is only admissible without counter pressure in the discharge line (port T).
With internal pilot oil return, the system pressure increases by the counter pressure
in the discharge line (port T) with increasing flow.
In this connection, observe the rules AD2000 - data sheet A2, point 6.3!
To ensure that this increase in system pressure caused by the flow does not exceed
10% of the set response pressure, the admissible flow has to be reduced dependent
on the counter pressure in the discharge line (port T), see "Data sheet 25802".
Transport and storage 19/52
CAUTION
Unsecured safety valves toppling over or falling down!
Unsecured safety valves may topple over or fall down and bruise or kill persons if
they are heavy.
ff Use the original packaging for transport.
ff Provide for a stable position during transport to the place of installation.
ff Use only suitable lifting gear for transport.
ff Wear your personal protective equipment.
ff Comply with the national laws and regulations regarding occupational health
and safety and transport.
Heavy components!
When lifting a safety valve with high weight, there is the danger of health hazards.
ff Use a suitable lifting, putting down and moving technique.
ff Products >15 kg are usually provided with lifting eyes for transport by means of
lifting gear. Use these lifting eyes.
ff Transport the safety valve complying with the safety instructions and using a
forklift or suitable lifting gear. Make sure that the lifting capacity of the lifting
gear is sufficient.
ff Observe the weight of the safety valve, the center of gravity and the intended
mounting and attachment points when transporting the valve.
ff During transport, secure the safety valve against toppling over.
ff Do not jam the safety valve.
ff Put the safety valve carefully onto the contact surface in order not to damage it.
Sharp edges!
Danger of cut injuries.
ff Wear suitable protective equipment when transporting the safety valve.
ff Secure the transported goods and the means of transport by means of suitable
measures.
20/52 Transport and storage
Notify your responsible sales contact person transport damage within one week.
The addresses of the sales subsidiaries can be found on the Internet at:
http:/www.boschrexroth.com/adressen
For transportation and storage of the product, always observe the environmental
conditions specified in "Data sheet 25802". Improper storage may damage the
safety valve.
Safety valves can be stored for up to 12 months under the following conditions:
ff Ensure a storage temperature range of +5...+40 °C.
ff The relative air humidity may not exceed 65%.
ff The storage rooms must provide 100% UV protection.
ff No ozone formation may occur near the storage facility.
ff The storage facilities must be free from etching substances and gases.
ff Do not store the safety valve outdoors but in a well-ventilated room.
ff Protect the safety valve against humidity, particularly ground humidity. Store the
safety valve on a shelf or on a pallet.
ff Store the safety valve protected against impacts and sliding and do not stack it.
ff Safety valves may be very heavy. In this connection observe the admissible load-
bearing capacities of your storage system.
ff Store the safety valve in the original packaging or comparable packaging in order
to protect it from dust and dirt.
ff All ports at the safety valve must be closed with closing elements.
ff After opening the transport packaging, it must be closed properly again for the
storage. Use the original packaging for storage
Assembly 21/52
Procedure after the After expiry of the maximum storage time, we recommend having the safety valve
expiration of the maximum checked by your competent Rexroth service. In case of questions regarding spare
storage time of 12 months parts, please contact the Rexroth service responsible for your safety valve, see
chapter 14.2 "List of addresses".
7 Assembly
CAUTION
High pressure!
Risk of injury due to parts shooting out during works at hydraulic accumulators
which have not been unloaded.
ff Carry out any work at the safety valve only after the system has been
depressurized.
ff Unload accumulators which may have been mounted at the system.
ff Check the system with test pressure according to ISO 4413.
ff Assembly and commissioning may only be carried out by specialists.
NOTICE
Penetrating humidity!
The housing of the valve electronics is closed. However, according to the applicable
protection class, fluids may enter and lead to faults and short-circuit. Safe function
of the safety valve is therefore no longer ensured.
ff When working at the safety valve, always ensure that no fluid can enter the
electronics.
22/52 Assembly
7.1 Unpacking
CAUTION
Parts falling out!
Risk of injury! If the packaging is opened improperly, parts may fall out and cause
injuries or damage of the parts.
ff Put the packaging on level, bearing ground.
ff Only open the packaging from the top.
The response pressure has been set by the manufacturer and secured by means of
lead seal and/or safety cap.
ff Check whether the sealing and/or the safety cap is undamaged.
Dispose of the packaging in accordance with the national conditions of your country.
Assembly 23/52
7.5 Accessories
Mating connectors For connection of the control line to safety valves of type DBW, mating connectors
according to EN 175301-803, optionally with and without circuitry, are available. For
more details, refer to "Data sheet 08006".
Valve mounting screws Table 8: Valve mounting screws for subplate mounting
For more details on the valve mounting screws, refer to chapter 7.7 "Assembly of
valves for subplate mounting".
WARNING
Faulty assembly of valve mounting screws!
Improperly mounted valve mounting screws may become loose during subsequent
operation and fly around due to the pressure and thus cause serious injuries.
ff Only pressurize your system after all valve mounting screws have been
completely and properly mounted according to the specifications.
CAUTION
Leaking hydraulic fluid!
Hydraulic fluid may leak during assembly and disassembly of safety valves.
Consequently, persons may slip or fall.
ff Immediately remove hydraulic fluid that has leaked out.
Sharp edges!
Safety valves may have sharp edges at the valve openings. During transport or
assembly/disassembly, cutting or abrasive injuries may result.
ff Wear corresponding protective clothing during transport.
ff Do not reach into valve openings!
24/52 Assembly
NOTICE
Wear, tear and malfunctions!
The cleanliness of the hydraulic fluid has a considerable impact on the cleanliness
and life cycle of the safety valve. Any contamination of the hydraulic fluid will result
in wear and malfunctions. Particularly foreign particles may damage the safety
valve.
ff Always ensure absolute cleanliness.
ff Install the safety valve free from any pollution.
ff Make sure that all connections, hydraulic lines and attachment parts are clean.
ff When sealing the connections, make sure that no contamination can get into the
system.
ff Ensure that no cleaning agents are able to penetrate the hydraulic system.
Assembly 25/52
WARNING
Faulty fastening of the safety valve!
Mounting of the safety valve using valve mounting screws of reduced stability
may cause the safety valve to become loose and lead to damage to persons and
property!
ff For reasons of stability, only valve mounting screws according to table 9
or of comparable quality (dimensions, property class) may be used. Screw
dimensions, property classes and tightening torques depend on the valve type
and the size.
Faulty assembly!
In case of faulty assembly due to a mix up of the hydraulic ports, the safety valve
loses its safety function!
ff Check whether the pressure to be limited is connected to port P and the
discharge line is connected to port T.
The mounting surfaces of the valve and the valve installation surface must be clean
and free from hydraulic fluid.
ff Use non-linting fabric for cleaning the valve installation surface.
26/52 Assembly
WARNING
Faulty assembly!
In case of faulty assembly due to a mix up of the hydraulic ports, the safety valve
loses its safety function!
ff Check whether the pressure to be limited is connected to port P and the
discharge line is connected to port T.
Faulty assembly!
A safety valve with threaded connection which you install under high mechanical
load generates additional forces during operation, which reduce the life cycle of the
safety valve and of the overall machine or system.
ff Mount the safety valve in a way that ensures that reaction forces which act on
the valve (e. g. due to vibration, shock) and hydraulic forces which act on the
connection lines (in particular when the line tears off) are absorbed by the
fixation in a risk-free manner.
The mounting surfaces of the valve and the valve installation surface must be clean
and free from hydraulic fluid.
ff Use non-linting fabric for cleaning the valve installation surface.
1. Tighten pipe fittings which are screwed directly into the safety valve. Observe the
tightening torque information by the pipe fitting manufacturer.
Assembly 27/52
To seal the port again using the plug screw, the screw must be tightened using the
tightening torque specified in table 11.
28/52 Assembly
WARNING
High electrical voltage due to incorrect connection!
Danger to life, risk of injury by electric shock!
ff The safety valve type DBW...5X/..E must only be connected by a specialized
electrician or under supervision of the same.
ff Switch off the voltage supply before all maintenance, repair or installation works
and secure it against restarting.
ff Provide for proper, safe PE connection.
Overheating!
A wrongly dimensioned fuse protection may lead to overheating during operation of
the safety valve.
ff A fuse appropriate for the solenoid's rated current (max. 3 x Irated according to
DIN 41571 and/or IEC 60127) or a protective motor switch with short-circuit
protection and thermal instantaneous tripping (setting to rated current) must
be connected to each directional valve solenoid as short-circuit protection.
The shut-off threshold of this fuse has to be equal to or greater than the
possible short-circuit current of the supply voltage source. The fuse may be
accommodated in the related supply unit or must be separately connected
upstream.
NOTICE
Uncontrolled disconnection and connection of plug-in connectors!
Device might be destroyed!
ff Before installation works, separate the device from the mains or from the
voltage source or de-energize it.
ff Do not plug in or pull the electric plug-in connector as long as the voltage supply
is activated.
Commissioning 29/52
8 Commissioning
WARNING
Faulty assembly, leaking hydraulic fluid!
Carelessly or incorrectly fastened safety valves may become loose during operation,
fall down and cause serious injuries. A hydraulic fluid jet may leak at incompletely
mounted hydraulic connections and connection lines and cause serious injuries.
ff Only commission the system after all hydraulic connections and the safety valve
have been completely and properly mounted according to the specifications.
ff Look out for defective sealing points and exchange defective seals immediately.
ff Wear personal protective equipment during the initial commissioning.
30/52 Operation
Information on the •• The released operating media and limitations of operation for your safety valve are
hydraulic fluid contained in "Data sheet 25802".
•• Bosch Rexroth offers the suitable seal designs for the hydraulic fluid used.
1. Switch the valve several times under operating pressure before placing it into full
operation. This will expel any remaining air from the valve. Mechanical damage
due to inadmissibly high acceleration of the hydraulic fluid and the control spool
is thus avoided and the valve's life cycle is increased.
You can also achieve the switching movement of the valve spool necessary for the
bleeding procedure by manually actuating the manual override. For further
information, see chapter 9.4 "Operating the optional manual override at the
directional valve".
Performing the leak test Check whether during operation hydraulic fluid leaks at the safety valve and at the
connections.
9 Operation
WARNING
Incorrect area of application!
The approval according to Pressure Equipment Directive and thus the safe pressure
limiting function are no longer applicable if the safety valve is used incorrectly or
outside its area of application.
ff Do not use the safety valve as high-response valve!
ff Possible unloading via the directional valve must not be applied for safety-
relevant functions!
ff If unloading is required for safety-relevant functions, an additional unloading
valve must be installed.
For information on the operation, please refer to the operating instructions for
the hydraulic system into which the safety valve is installed.
Operation 31/52
Pressure peaks in the joint return line of more than one valve may cause unintended
spool movements and thus unintended switching processes. It is recommended to
use separate return lines.
You can set safety valves which have been provided with a hand wheel or rotary knob
to a lower response pressure without damaging the lead seal. To do this, the system
into which the safety valve is installed needs to be equipped with a pressure gauge
which indicates the pressure at port P or a pressure gauge has to be connected
temporarily to the additional M port, which is normally closed by a plug screw.
The response pressure of a safety valve may only be within the specified pressure
range due to the installed compression spring. The maximum flow indicated by the
component marking can only be utilized within this pressure range.
1. Temporarily deactivate or remove any other pressure limiting devices which are
installed in the system and have an impact on channel P and seal any openings
which were caused by this.
2. For systems without a pressure gauge installed in channel P, connect a pressure
gauge at the additional M port.
3. Unload the valve spring as described in chapter 10.2.4 "Unloading the safety
valve", screw in the adjustment spindle again as far as possible but do not tighten
the lock nut yet after unloading the spring.
4. Switch on the system and wait until the system pressure has built up.
5. Set the desired lower response pressure:
Screw out the adjustment spindle so far that the pressure gauge indicates the
desired pressure. When you screw out the valve spindle, the safety valve opens
and limits the system pressure.
6. Tighten the lock nut clockwise using a manual torque wrench with an accuracy of
± 10% and the tightening torque indicated in the table.
32/52 Operation
7. Switch off the system, let the pressure decrease, depressurize any provided
pressure accumulators, if applicable. Remove the temporarily installed pressure
gauge and seal the additional M port using the plug screw. Tightening torques see
table 11.
8. Return any other pressure limiting devices which are installed in the system and
have an impact on channel 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.
Operation 33/52
Interpolation of 1. At the axis referred to as pT, mark 1/10 of the value of response pressure pA.
intermediate values from 2. From the marked point, draw a straight line within the interpolation area to the
the diagram zero position flow on the axis referred to as qVmax (here 130 /min for interpolation
area I and/or 200 l/min for interpolation area II).
3. Mark the system flow to be secured at the axis referred to as qVmax.
4. Read off the maximum admissible counter pressure for this value using the line at
the axis referred to as pT drawn before.
34/52 Operation
Read off the maximum admissible counter pressure of approx. 11.5 bar from the
diagram (see arrows, dashed characteristic curve).
Operation 35/52
36/52 Operation
CAUTION
Incorrect operation of the manual override!
There is the risk of damaging the valve and/or incorrect operation may result in
dangerous movements of the connected actuators.
ff Only operate the manual override if it is ensured that this will not trigger any
dangerous working movement of the connected actuator.
ff Do not use sharp-edged tools to operate the manual override. There is the
danger of damaging sealing surfaces at the solenoid.
The manual override is only intended for short-time manual operation and must not
be brought into a certain spool position for a longer period or permanently by means
of mechanical devices.
The manual override is not suitable for frequently recurring manual operations!
Maintenance and repair 37/52
NOTICE
Solvents and aggressive cleaning agents!
Aggressive cleaning agents may damage the seals of the safety valve and accelerate
aging.
ff Never use solvents or aggressive cleaning agents.
For cleaning and care of the safety valve, observe the following:
ff Remove external coarse dirt and keep sensitive and important parts clean.
ff Only clean the safety valve using a damp, non-linting cloth. Only use water and a
mild cleaning agent, if necessary, to do so.
NOTICE
Dirt and foreign particles in the safety valve!
Penetrating dirt and foreign particles in the safety valve lead to wear and
malfunctions. Safe function of the safety valve is therefore no longer ensured.
ff During all works at the safety valve, provide for absolute cleanliness in order to
prevent foreign particles like e. g. welding beads or metal chips from getting into
the hydraulic lines.
ff Do not use linting fabric for cleaning.
ff Ensure that no cleaning agents are able to penetrate the hydraulic system.
ff Flush the hydraulic system if necessary. Replace the fluid filter or the hydraulic
fluid.
38/52 Maintenance and repair
WARNING
Improper unloading of the safety valve!
Improper unloading of the safety valve in the system may cause hazards or faults.
ff Only qualified personnel (see chapter 2.4 "Qualification of personnel") is
authorized to unload the safety valve.
ff Observe the operating instructions and/or the functional set-up of the system.
ff 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.
Maintenance and repair 39/52
1 2 3
Unloading the valve on 1. Depressurize the system, verify the depressurized condition by means of a
a separate test stand pressure gauge so that the valve can be removed in a risk-free manner.
(recommended) 2. Remove the valve from the system and assemble it on a suitable test stand
considering the necessary tightening torques.
3. Release the locking of the adjustment spindle (2):
release the lock nut (1) by means of an open-end wrench by rotating it
counterclockwise.
4. Purging the safety valve:
Screw out the adjustment spindle (2) to the stop by rotating the rotary knob (3)
counterclockwise. Now allow free flow through the safety valve for approx. 5...10
seconds so that dirt particles that might exist at the valve seat are removed by
the flow.
5. Screw in the adjustment spindle (2) by rotating the rotary knob (3) clockwise so
that the lock nut (1) rests against the valve body without any play. If the response
pressure is to be newly set, rotate the adjustment spindle so that at a suitable,
calibrated pressure gauge with the largest accuracy possible, the original
response pressure known from the valve component marking is displayed.
6. Hold the rotary knob (3) and tighten the lock nut (1) by means of a manual torque
wrench applying the specified tightening torque by rotating it clockwise.
7. Depressurize the test stand (verify by means of pressure gauge) so that the valve
can be removed in a risk-free manner.
8. Remove the valve from the test stand and assemble it on the system considering
the necessary tightening torques.
40/52 Maintenance and repair
Unloading the valve while 1. Release the locking of the adjustment spindle (2):
it remains in the system release the lock nut (1) by means of an open-end wrench by rotating it
counterclockwise.
2. Purging the safety valve:
Screw out the adjustment spindle (2) to the stop by rotating the rotary knob (3)
counterclockwise. Now allow free flow through the safety valve for approx. 5...10
seconds so that dirt particles that might exist at the valve seat are removed by
the flow.
3. Screw in the adjustment spindle (2) by rotating the rotary knob (3) clockwise so
that the lock nut (1) rests against the valve body without any play.
4. Hold the rotary knob (3) and tighten the lock nut (1) by means of a manual torque
wrench applying the specified tightening torque by rotating it clockwise.
10.3 Repair
WARNING
Damage to persons and property caused by improper repair!
In case of improper repair, the safety function of the safety valve is no longer given
in subsequent operation.
ff Only repair measures listed in chapter 10 "Maintenance and repair" are
admissible.
ff Only qualified personnel (see chapter 2.4 "Qualification of personnel") is
authorized to repair the safety valve.
ff The sealing and/or the safety cap must not be removed.
If hydraulic fluid continues to leak after re-installation of the safety valve, the safety
valve itself is defective. In this case, send the safety valve to the manufacturer for
repair.
Maintenance and repair 41/52
10.3.1 Mounting screws for the connection of main and directional valve with
valves DBW...5X/...E
During exchange of the seals between directional valve and main valve, you must
loosen the mounting screws of the directional valve.
Regarding the re-assembly after seal exchange, please note that for the assembly,
you may only use the original mounting screws or screws of the specification given in
table 17. Observe the specified tightening torque!
Table 17: Mounting screws for the connection of main and directional valve with valves
DBW...5X/...E
Seal kit for the valve Table 18: Seal kit for the valve connection surface
connection surface (valves Valve type + size NBR FKM
for subplate mounting) Component marking
DB(W)10...5X/...E R961001280 R961001283
851
DB(W)20...5X/...E R961001289 R961001290
852
DB(W)30...5X/...E R961001291 R961001293
853
Seal for switching shock Table 19: Seal kit for the sandwich plate for switching shock damping
damping sandwich plate Valve type NBR FKM
DBW...5X/...S6...E R900722866 R900722867
Seal for directional Table 20: Seal for directional spool valve NG6
spool valve NG6 Valve type NBR FKM
DBW...5X/...6E...E R900357573 R900357574
Seal for directional Table 21: Seal for directional seat valve NG6
seat valve NG6 Valve type NBR FKM
DBW...5X/...6SM...E R961000683 R961000684
42/52 Disassembly and replacement
Seal for measuring port Table 22: Seal for measuring port NG10-30
NG10-30 Valve type NBR FKM
DB(W)...5X/...E R900012467 R902602257
The spare parts are available from the address specified in chapter 14.2 "List of
addresses".
WARNING
Pressurized and energized system parts!
When working on pressurized and energized system parts, there is the danger of
injury by leaking hydraulic fluid or electric shock.
ff Ensure that the hydraulic system is depressurized and the electrical control is
de-energized before the disassembly.
CAUTION
Incompletely mounted valve components falling down!
Incompletely disassembled valve components may fall down and cause injuries.
ff During the disassembly, secure the safety valves against falling down.
1. Switch off your system, de-energize and depressurize the system and secure the
system against restarting before all disassembly works.
2. Unload the hydraulic accumulators, if applicable.
3. Provide for a clean environment during the disassembly.
4. Prepare a container or a pan for collecting the leaking hydraulic fluid.
5. Detach the safety valve from the pipelines, flange connections or the subplate
using appropriate tools; collect any hydraulic fluid that might leak in the provided
tank. Dispose of the hydraulic fluid properly.
WARNING! Heavy components! When lifting safety valves or components with high
weight, there is the danger of damage to property and personal injuries.
ff Please observe the safety instructions in chapter 6 "Transport and storage".
Disposal 43/52
6. If the device is to be returned to the manufacturer for repair, please close the
ports using the transport protection or protect it using equivalent packaging in
order to avoid contamination and damage.
7. Close the connection 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".
12 Disposal
44/52 Extension and modification
12.3 Packaging
Upon request, reusable systems can be used for regular deliveries.
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.
12.5 Recycling
Due to the high metal share, hydraulic products can mostly be recycled. In order to
achieve an ideal metal recovery, disassembly into individual assemblies is required.
Troubleshooting 45/52
14 Troubleshooting
ff Try to get a clear idea of the cause of the error. If necessary, ask the actual
(machine) operator.
46/52 Troubleshooting
Fault table The safety valve is not sensitive to faults as long as the specified application
conditions are complied with, in particular the oil quality and the operating
temperature.
If the response A safety valve with insufficiently Select and order a safety valve with
pressure is exceeded, dimensioned flow was installed. suitable specified flow.
the system pressure
increases excessively With type DB(W)..G...5X/...E: Check the ports; connect the safety
even though The valve ports are mixed up. valve correctly. Observe the connection
the safety valve designations P and/or A (pressure
responds. port) and T and/or B (port of the
During bleeding, discharge line).
the system pressure
The P port of the safety valve Use larger supply pipes
exceeds the
is connected via a line with (increase supply cross-sections);
10% limit above
excessive flow resistance. avoid a deflection of flow.
the maximum
The T port of the safety valve Use larger discharge pipes (increase
admissible pressure
is connected via a line with outlet diameters), avoid a deflection of
(see EC Pressure
excessive flow resistance. flow, observe the maximum admissible
Equipment Directive
counter pressure in the discharge
2014/68/EU,
line, see chapter 9.3 "Operation with
Appendix I,
counter pressure in the discharge line".
chap. 7.3).
The viscosity of the hydraulic Check whether a suitable hydraulic
fluid is outside the valve fluid can be used in the system and
specification. exchange the hydraulic fluid.
Safety valve response A safety valve with unsuitable Check the specified response pressure
pressure is too low. response pressure has been of the safety valve by means of the last
installed. figure of the component marking at the
safety valve or name plate. Select and
order a safety valve with suitable
response pressure.
The difference between Check whether the system can be
operating pressure and operated at lower operating pressure
response pressure of the safety or select and order a safety valve with
valve is too small. suitable response pressure.
Troubleshooting 47/52
48/52 Troubleshooting
Other leakage at the Directional valve /switching Send valve to the authorized facility
directional valve or at shock damping valve defective for repair. Please contact your regional
the switching shock Bosch Rexroth representative.
damping valve
Rotary handle is Transport damage, improper Send valve to the authorized facility
destroyed handling for repair. Please contact your regional
Bosch Rexroth representative.
Troubleshooting 49/52
The addresses of our sales and service network and sales organizations can be found
at www.boschrexroth.com/adressen
Ordering address for A possibly missing setting certificate can be requested from the Rexroth Quality
setting certificate Assurance at the following address:
Bosch Rexroth AG
Department LoP1/QMM7
Zum Eisengießer 1
97816 Lohr am Main
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.
50/52 Declaration of conformity
15 Declaration of conformity
Alphabetical index 51/52
16 Alphabetical index ▶▶ N
Name plate 15
▶▶ O
▶▶ A
Obligations of the machine end-user
Abbreviations 7
12
Accessories 23
Operation 30
AD 2000 7
Order confirmation 24
Assembly 21
▶▶ P
▶▶ C
Pressure gauge 31
Cleaning agents 37
Pressure range 31
Commissioning 29
Protective equipment 12
Component marking 16, 17
Corrosion 11
▶▶ Q
Counter pressure in the discharge
Qualification 9
line 32
▶▶ R
▶▶ D
Repair 37
Damage to property 13
Required documentation 5
Declaration of conformity 50
Response pressure 31
Designations 7
Disposal 43
▶▶ S
Safety instructions 7
▶▶ E
–– General 9
Environmental conditions 22
–– Product-dependent 10
Extension and modification 44
–– Signal word 6
Scope of delivery 14
▶▶ F
Sealing 22
Flange connection 26
Spare parts 41
Functional safety 10
Storage 19
Subplate mounting 25
▶▶ H
Symbols 6
Hydraulic accumulator 21
System pressure 31
▶▶ I
▶▶ T
Identification 15
Test pressure 21
Installation conditions 22
Tools 22
Installation position 22
Transport 19
Intended use 7
Transport damage 20
Troubleshooting 45
▶▶ L
Lifting gear 20
▶▶ U
Limitations of use 18
Unloading 31
▶▶ M
▶▶ W
Maintenance 37
Warranty 13
Maintenance interval 38
Manual override 36
Modification 44
M port 27
RE25802-B/07.16, DB(W)...5X/...E, Bosch Rexroth AG
Bosch Rexroth AG
Zum Eisengießer 1
97816 Lohr am Main
Germany
Phone +49 (0) 9352 18-0
[email protected]
www.boschrexroth.com