Explosion-proof hydraulic valves, Type WE...VE1...

Transcription

1 Explosion-proof hydraulic valves, Type WE...VE1... RE VE1-B0/03.15 Replaces: -.- Material Number: R Operating instructions

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3 1/14 Directional spool valves, direct operated, with solenoid actuation RE VE1-B1/03.15 Type WE VE1 Size 6 Component series 6X Maximum operating pressure 350 bar Maximum flow 70 l/min Actual product may differ For explosive areas Part I Data sheet Information on explosion protection: Area of application according to NEC 505: Class I, Zone 1 Type of protection of the valve solenoid: AEx e mb IIC T4 Gb according to ANSI / ISA ANSI / ISA What you need to know about these operating instructions These operating instructions apply to the explosion-proof version of Rexroth valves and consist of the following two parts: Part I Data sheet VE1-B1 Operating instructions VE1-B0 Part II Product-specific instructions VE1-B2 For further information on the correct handling of Rexroth hydraulic products, refer to Data sheet General product information on hydraulic products.

4 2/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Table of contents Features 2 Ordering code and scope of delivery 3 Symbols 4 Function, section 5 Technical data 6, 7 Information on explosion protection 7 Electrical connection 8, 9 Performance limits 10 Characteristic curves 11 Dimensions 12 Installation conditions 13 Features 4/3-, 4/2- or 3/2-way version For proper use in explosive atmospheres Porting pattern according to ISO 3/2/ Subplates available in FE/ZN version (see page 12) Wet-pin DC solenoids Solenoid coil can be rotated by 90 Electrical connection as a single connection with pipe thread NPT 1/2" Manual override, optional

5 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 3/14 Ordering code and scope of delivery WE 6 6X E VE1 Z2 3 main ports = 3 4 main ports = 4 Size 6 = 6 Symbols e.g. C, E, EA, EB, etc; possible versions, see page 4 Component series 60 to 69 (60 to 69: unchanged installation and connection dimensions) Spring return Without spring return without spring return with detent High-power solenoid wet-pin, with detachable solenoid coil Direct voltage 24 V Direct voltage 110 V With manual override (standard) without manual override = 6X = no code = O = OF = E = G24 = G110 = N = no code No code = NBR seals V = FKM seals Note: Observe compatibility of seals with hydraulic fluid used. No code = Without throttle insert B08 = Throttle Ø 0.8 mm B10 = Throttle Ø 1.0 mm B12 = Throttle Ø 1.2 mm Use if flow > performance limit of the valve, effective in channel P Electrical connection Z2 = Solenoid with terminal box and cable gland, For details see chapter Electrical connection VE1 = Increased Safety explosion protection, For details, see information on explosion protection page 7 Note: Valve operating instructions included in the scope of delivery.

6 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 4/14 Symbols 1) Example: Symbol E with spool position a ordering code..ea.. 2) For valves with G110 DC solenoids and detent, only symbols C46/OF and D46/OF are admissible. Further control spools on demand

7 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 5/14 Function, section Directional valves of type WE are solenoid operated directional spool valves. They control the start, stop and direction of a flow. The directional valves basically consist of housing (1), one or two solenoids (2), control spool (3), and one or two return springs (4). In the de-energized condition, the control spool (3) is held in the central position or in the initial position by the return springs (4) (except for impulse spools). The control spool (3) is actuated by wet-pin solenoids (2). To ensure proper functioning, make sure that the pressure chamber of the solenoid is filled with oil. The force of the solenoid (2) acts via the plunger (5) on the control spool (3) and pushes the latter from its rest position to the required end position. This enables the required direction of flow from P A and B T or P B and A T. After solenoid (2) was de-excited, the return spring (4) pushes the control spool (3) back to its rest position. An optional manual override (6) allows the control spool (3) to be moved without solenoid energization. Type 4WE 6.. 6X/O...VE1... (only possible with symbols A, C and D) This version is a directional valve with two spool positions and two solenoids without detent. In the de-energized condition, there is no defined spool position. Type 4WE 6.. 6X/OF... VE1... (impulse spool, only possible with symbols A, C and D) This version is a directional valve with two spool positions, two solenoids and one detent. It alternately locks the two spools positions and the solenoid therefore does not need to be permanently energized. Note: Pressure peaks in the tank line to two or several valves can result in unintended control spool movements in the case of valves with detent! We therefore recommend that separate return lines be provided or a check valve installed in the tank line. Due to the design principle, internal leakage is inherent to the valves, which may increase over the life cycle. Prevent the tank pipe from running dry. With corresponding installation conditions, a preload valve (preload pressure approx. 2 bar) must be installed. Throttle insert (type 4WE 6..6X/ VE1../B.. ) The use of a throttle insert is required when, due to prevailing operating conditions, flows can occur during the switching processes, which exceed the performance limit of the valve. It is inserted in channel P of the directional valve. Seal ring a b 6 Type 4WE 6 E6X/.E..NVE1Z A (P) T B

8 6/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Technical data General Installation position any Ambient temperature range Storage temperature range Admissible vibration load Hz amplitude 0.05 g 2 /Hz (10 g RMS) Weight 2.6 (with 1 solenoid); 4.0 (with 2 solenoids) Surface protection Galvanic coating Hydraulic Maximum operating pressure Port A, B, P bar 350 Port T bar 210 With symbols A and B, port T must be used as the leakage oil connection if the operating pressure exceeds the admissible tank pressure. Maximum flow l/min 70 Flow cross-section with symbol Q approx. 6% of nominal cross-section (Spool position 0) with symbol W approx. 3 % of nominal cross-section Hydraulic fluid See table below Hydraulic fluid temperature range C (NBR seals) (FKM seals) Viscosity range mm 2 /s Maximum admissible degree of contamination of the hydraulic fluid cleanliness class according to ISO 4406 (c) Class 20/18/15 1) Hydraulic fluid Classification Suitable sealing Standards Data sheet materials Mineral oils HL, HLP, HLPD, HVLP, HVLPD NBR, FKM DIN Bio-degradable Insoluble in HETG NBR, FKM ISO water HEES FKM Soluble in water HEPG FKM ISO Important information on hydraulic fluids: For more information and data about the use of other hydraulic fluids, refer to the data sheets above or contact us! There may be limitations regarding the technical valve data (temperature, pressure range, life cycle, maintenance intervals, etc.)! Ignition temperature of the hydraulic fluid used > 180 C 1) The cleanliness classes specified for the components must be adhered to in hydraulic systems. Effective filtration prevents faults and at the same time increases the life cycle of the components. For the selection of the filters see

9 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 7/14 Technical data Electric Voltage type Direct voltage Available voltages V 24, 110 Voltage tolerance (nominal voltage) % ± 10 Admissible residual ripple % < 5 Duty cycle/operating mode according to VDE 0580 S1 (continuous operation) Switching time according to ISO 6403 ON ms OFF ms Maximum switching frequency 1/h Nominal power at ambient temperature 20 C W 17 Maximum power at 1.1 x nominal voltage and ambient temperature 20 C W 20.6 Protection class according to NEMA 250 NEMA TYPE 4 2) 2) If the electrical connection is correctly installed Information on explosion protection Area of application according to NEC 505 Class I, Zone 1 Maximum surface temperature 3) Temperature class Type of protection of the valve solenoid according to ANSI / ISA ANSI / ISA ) Surface temperature > 50 C, provide contact protection C 135 T4 AEx e mb IIC T4 Gb FM certificate Ambient temperature range C Special conditions for safe use The maximum temperature of the valve casing surface is 125 C. This must be considered when selecting the connection cable or to prevent the connection cable from coming into contact with the casing surface.

10 8/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Electrical connection The type-tested valve solenoid of the valve is equipped with a terminal box and a type-tested cable gland. The connection is polarity-independent Note When establishing the electrical connection, the protective earthing conductor (PE ) has to be connected correctly. 3 Properties of the connection terminals and mounting elements Item Function Connectable line cross-section 1 Operating voltage connection Single-wire mm 2 finely stranded mm 2 2 Connection for protective earthing conductor Single-wire 2.5 mm 2 max. finely stranded 1.5 mm 2 max. 3 Connection for potential equalization conductor Single-wire 6 mm 2 max. finely stranded 4 mm 2 max. 4 Adapter with internal thread NPT1/2 Connection line Line type non-armored cables and lines (outer sheath sealing) Temperature range C -20 > +100

11 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 9/14 Electrical connection Circuit diagram Direct voltage, polarity-independent Overcurrent fuse and switch-off voltage peaks Note: Corresponding to the rated current, a fuse according to IEC and/or UL has to be connected upstream of every solenoid coil (max. 3 x Inom). The shut-off threshold of the fuse has to match the prospective short-circuit current of the supply source. The prospective short-circuit current of the supply source may amount to a maximum of 1500 A. This fuse may only be installed outside the explosive area or must be of an explosion-proof design. When inductivities are switched off, voltage peaks result which may cause faults in the connected control electronics. For this reason, the valve solenoids contain an interference protection circuit which dampens this voltage peak to the voltage value shown in the table. Prescribed external miniature fuses according to IEC Voltage data in the valve type code Nominal voltage of valve solenoid Rated current valve solenoid Rated current (fuse) Rated voltage (fuse) Maximum voltage value upon switch-off Interference protection circuit G24 24 V DC A DC 800 ma 250 V -90 V G V DC A DC 200 ma 250 V -390 V Suppressor diode bi-directional Note: Time current characteristic of the external miniature fuse: Quick-acting (F) according to IEC Prescribed external miniature fuses according to UL Voltage data in the valve type code Nominal voltage of valve solenoid Rated current valve solenoid Rated current (fuse) Rated voltage (fuse) Maximum voltage value upon switch-off Interference protection circuit G24 24 V DC A DC 1 A 250 V -90 V G V DC A DC 200 ma 250 V -390 V Suppressor diode bi-directional Note: Time current characteristic of the external miniature fuse: Quick-acting (F) according to UL

12 10/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Performance limits (measured using HLP46, ϑ oil = 40 C ± 5 C) Note: The stated switching power limits apply to operation with two directions of flow (e.g. from P A and simultaneous return flow from B T). Due to the flow forces acting within the valves, the permissible switching power limits may be considerably lower with only one direction of flow (e.g. from P A while port B is blocked.) (In such cases, please consult us.) The switching power limits were determined while the solenoids were at operating temperature, at 10% undervoltage and without tank pre-loading. Valves with G24 DC solenoids Operating pressure in bar Flow in l/min Characteristic Symbol curve 1 A, B 2 J, L, U 3 V 4 D, C, Y 5 Q, W 6 E 7 A/O, A/OF 8 F, P 9 T 10 G 11 H, D/O 12 R 1), M Valves with G110 DC solenoids Operating pressure in bar Flow in l/min Characteristic Symbol curve 1 A, B 2 J, L, U, Q, W 3 V 4 D, C, Y 5 C46/OF, D46/OF 6 E 7 A/O 8 F, P, T 9 R 1) 10 G 11 H 12 M, D/O, C/O 1) Return flow from actuator to tank

13 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 11/14 Characteristic curves (measured with HLP46, ϑ oil = 40 C ± 5 C) Pressure differential in bar p-q V characteristic curves Flow in l/min 4 Symbol H in central position P T 9 Symbols G and T in central position P T 10 Symbol R in spool position B A Symbol Direction of flow P A P B A T B T A, B 5 5 C, C D, D46, Y E F T H J, Q L M P R V W U G

14 12/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Dimensions (dimensions in mm) Ø9,4 Ø5, ,2 3 13,6 F1 F2 F4 G F a b A T B P 0,01/100 Rzmax 4 Required surface quality of the valve contact surface 1 Name plate 2 Identical seal rings for ports A, B, P, T 3 Plug screw for valves with one solenoid 4 Mounting nut with hexagon SW32 tightening torque M A = 4+1 Nm 5 Porting pattern according to ISO (with locating hole for locating pin ISO x8-St, material no. R , separate order) 6 Space required to remove the coil Valve mounting screws (separate order) For reasons of stability, exclusively the following valve mounting screws are to be used: 4 hexagon socket head cap screws ISO 4762-M5x flZn-240h-L (friction coefficient according to VDA ) Material no. R Subplates (dimensions according to data sheet separate order) (Without locating hole) G 341/01 FE/ZN (G1/4) G 342/01 FE/ZN (G3/8) G 502/01 FE/ZN (G1/2) (With locating hole) G 341/60 FE/ZN (G1/4) G 342/60 FE/ZN (G3/8) G 502/60 FE/ZN (G1/2) Note: Subplates are not components in the sense of directive 94/9/EC and can be used after the manufacturer of the overall system has assessed the risk of ignition. The G...FE/ZN versions are free from aluminum and/or magnesium and galvanized.

15 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 13/14 Installation conditions (dimensions in mm) Subplate dimensions Thermal conductivity of the subplate Minimum distance between the longitudinal valve axes Individual assembly Bank assembly Minimum dimensions Minimum cross-section Length 64, width 58, height 25 Height 60, width W/mK (EN-GJS-500-7) 55 mm Schematic diagram Individual assembly Bank assembly

16 14/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Notes Bosch Rexroth AG Hydraulics Zum Eisengießer Lohr am Main, Germany Phone +49 (0) / 18-0 documentation@boschrexroth.de 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 our consent. The data specified only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

17 RE VE1-B1 WE VE1 Hydraulics Bosch Rexroth AG 15/14 Bosch Rexroth AG Hydraulics Zum Eisengießer Lohr am Main, Germany Phone +49 (0) / 18-0 documentation@boschrexroth.de 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 our consent. The data specified only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

18 16/14 Bosch Rexroth AG Hydraulics WE VE1 RE VE1-B1 Bosch Rexroth AG Hydraulics Zum Eisengießer Lohr am Main, Germany Phone +49 (0) / 18-0 documentation@boschrexroth.de 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 our consent. The data specified only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

19 1/20 Directional spool valves, direct operated, with solenoid actuation RE VE1-B2/03.15 Type WE...VE1... Size 6 Component series 6X Maximum operating pressure 350 bar Maximum flow 70 l/min Actual product may differ For explosive areas Operating instructions Part II Product-specific instructions What you need to know about these operating instructions These operating instructions apply to the explosion-proof version of Rexroth valves and consist of the following two parts: Part I Data sheet VE1-B1 Operating instructions VE1-B0 Part II Product-specific instructions VE1-B2 For further information on the correct handling of Rexroth hydraulic products, refer to Data sheet General product information on hydraulic products.

20 2/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 Contents Page 1 Scope of delivery 3 2 Important general information Conventions in this product information 3 3 Responsibilities Liabilities and warranty Responsibilities of the machine end-user/user Copyright 4 4 Important general safety instructions Staff requirements, duty of care Residual risks and protective measures Intended use Disposal Use in explosive areas 6 5 Amending general safety instructions Information on the name plate and the valve solenoid Special residual risks and protective measures 10 6 Assembly and (initial) commissioning Safety instructions for assembly and (initial) commissioning Rotating the solenoid coil by ± Assembly Establishing the electrical connection Initial commissioning, re-commissioning 14 7 Disassembly 14 8 Operation Operating the optional manual override 15 9 Troubleshooting Inspection and maintenance Repair and spare parts Safety instructions regarding repairs Rectifying external leakages Available spare parts Contacts for repairs and spare parts: Accessories Available accessories Ordering address for accessories and valves 18

21 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 3/20 1 Scope of delivery For the scope of delivery of the valve, please refer to the Data sheet of this valve (Part I of these operating instructions). 2 Important general information 2.1 Conventions in this product information Cross-references are shown in italics. DANGER This symbol indicates an imminent danger which will immediately result in most serious bodily injuries or death unless it is avoided. WARNING This symbol indicates an imminent danger which can result in most serious bodily injuries or death unless it is avoided. CAUTION This symbol indicates a possible danger which can result in minor or serious bodily injuries and/or damage to property. NOTE This symbol refers to additional information. 3 Responsibilities 3.1 Liabilities and warranty Bosch Rexroth AG shall not be liable for any damages resulting from nonobservance or incomplete observance of these operating instructions. In case of unauthorized changes the warranty becomes invalid. Bosch Rexroth shall only be liable if the delivery was faulty. Bosch Rexroth shall not be liable if faults are caused by the customer replacing parts with parts that are similar but not the identical parts prescribed by the manufacturer. For further details on the warranty and manufacturer's warranty, please refer to our general terms of delivery or your contract documents. 3.2 Responsibilities of the machine end-user/user The hydraulic fluid on mineral oil basis is water-polluting and inflammable. It may only be used if the corresponding safety data sheet of the manufacturer is available and all measures prescribed therein have been realized. If leakage at the valve can lead to water or soil contamination, the valve must be put into a suitable collecting pan. The machine end-user is responsible for: the valve only being used according to the intended use as defined in these operating instructions. that the valve is only used in such a way that the technical data, operating and environmental conditions stated in these operating instructions are complied with. In particular the limit values stated in the data sheet may not be exceeded if humanly possible and in compliance with the operating instructions. the applicable provisions and directives on explosion protection being complied with. If the valve is a component of another product, e.g. of a hydraulic system, the person responsible for this other product (e.g. the designer / system constructor) shall make sure that the valve is only used according to the intended use as defined in these operating instructions. that the valve is only used in such a way that the technical data, operating and environmental conditions stated in these operating instructions are complied with. In particular the limit values stated in the data sheet may not be exceeded if humanly possible and in compliance with the operating instructions. the applicable provisions and directives on explosion protection being complied with.

22 4/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 3.3 Copyright Without the express prior written approval of Bosch Rexroth AG, these operating instructions may not be copied electronically or mechanically, distributed, changed, transmitted, translated into another language or otherwise translated, used or copied - neither wholly nor in part. 4 Important general safety instructions 4.1 Staff requirements, duty of care General requirements, qualifications Persons to be instructed or trainees or persons under supervision under the age of 18 may not carry out any work on Rexroth valves. This shall not apply to young persons with a minimum age of 16 if work with Rexroth valves is required to reach the training objective. the protection of the young person is guaranteed in the form of supervision by an experienced expert. only equipment, tools and protective equipment are used that prevent injuries. An expert is someone who, due to their technical training, knowledge and experience, can assess the tasks assigned to them, recognize possible dangers and take the required measures to prevent any danger of accidents Staff requirements regarding classification into zones and device groups According to paragraph 505 NEC, the classification into zones and device groups must always be supervised by a Qualified Registered Professional Engineer Maintenance staff requirements Maintenance measures may be required to keep the valve functional. Maintenance measures include inspection, maintenance and repair of hydraulic and electronic components. These various tasks require certain minimum qualifications of the staff. For inspections of hydraulic components the staff has to meet the following requirements: They have to be instructed in the task. Special hydraulic expert knowledge is not required. For maintenance work on hydraulic components the staff has to meet the following requirements: They have to be instructed in the respective task. They need special hydraulic expert knowledge to carry out maintenance tasks. For repair work on hydraulic components the staff has to meet the following requirements: They must be hydraulics experts who have been instructed in the task according to the above definition. They need to be able to understand the operation of the entire hydraulic system, of subsystems and the way it interacts with the machinery. They need to be able to read hydraulic circuit diagrams, interpret sub-functions of individual symbols and understand functional diagrams. They need knowledge about the function and structure of hydraulic elements. The following applies to works on the electric system: According to paragraph 505 NEC, wiring must always be supervised by a Qualified Registered Professional Engineer. Works on the electronic equipment may only be carried out according to the electrical regulations by an authorized electrician or an instructed person who is supervised by an authorized electrician.

23 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 5/ Residual risks and protective measures DANGER Danger zone Residual risk Precaution(s), safety instructions Connections and pressure lines (pipe and hose lines) Surfaces of components and pressure lines Electric components Risk of injury or danger to life due to hydraulic fluid ejection under high pressure during maintenance work Risk of burning due to high surface temperatures Electric shock Loss of explosion protection Failure due to excessive moisture as a result of cleaning with a high-pressure washer Depressurize the hydraulics before starting commissioning and unload existing pressure accumulators, if applicable. Immediately repair leakages. Allow hydraulic components to cool before starting maintenance work. Wear protective clothing. Work on electric components only when they are de-energized. De-energize electrical connections prior to installation and disassembly. Any work requiring the disassembly of product components may only be carried out in the scope specified in this part. Protect the valve from the high-pressure water jet. Unprotected handling of hydraulic fluid is harmful to health. Please observe the safety instructions of the manufacturer of the hydraulic fluid used and the respective safety data sheets. CAUTION Danger zone Residual risk Precaution(s), safety instructions Connections and pressure lines (pipe and hose lines) Water or soil contamination due to leakage Collecting pan. Immediately repair leakages. NOTE See also 3.2 Responsibilities of the machine end-user/user.

24 6/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 4.3 Intended use The valve is designed and constructed for the control of energy and signals using oil flow. Store the valve only in a dry and dust-free environment which is free from corrosives and fumes and which is subject to a low degree of humidity and only minor temperature changes. For storage exceeding 6 months, we recommend filling in clean conservation oil. NOTE The factory corrosion protection is sufficient if the valve is stored under the stated conditions and if no condensate or leakage water may enter the valve. The valve may only be operated with the hydraulic fluids stated in the data sheet. Please consult us for information on the use of the valve with other hydraulic fluids. The valve may only be operated in a technically perfect condition and used as described in these operating instructions. The connection conditions, application conditions and performance data defined in these operating instructions must not be changed. NOTE If you intend to use the valve with other connection, application or performance data than those defined by Bosch Rexroth AG in these operating instructions, please contact Bosch Rexroth AG beforehand. The valve must not be used with other connection, application and performance data than those defined in these operating instructions without the written approval by Bosch Rexroth AG. The valve may only be modified in the scope specified in this part. 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. Persons under the influence of alcohol, other drugs or pharmaceuticals that may affect their ability to react must not operate or maintain Rexroth valves. 4.4 Disposal Empty hydraulic products and dispose of them as metal waste. Collect any remaining hydraulic fluid and dispose of it according to the instructions in the safety data sheet of the hydraulic fluid. Dispose of electronic products according to the valid regulations. 4.5 Use in explosive areas The valve is intended to be used in explosive gas atmospheres. Group IIC for explosive gas atmospheres except mine workings susceptible to firedamp. Encapsulation protection class mb ANSI / ISA Equipment protection by increased safety e ANSI / ISA NEC 505 labeling: Class I, Zone 1, AEx e mb IIC T4 Gb DANGER The hydraulic product may only be used under the application conditions stated in the data sheet, information on the explosion protection or in areas with lower requirements Classification of explosive areas The user / machine end-user has to classify explosive areas according to NEC (National Electrical Code) into zones (class). The following table describes the zones, groups and temperature classes of Class I (flammable gases, fumes or vapors) in more detail. During use, also observe the other information on the explosion protection in the data sheet.

25 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 7/20 Gases, fumes or vapors Classification class I NEC CEC Zone 0 Zone 1 Zone 2 Class I Groups NEC CEC J Areas, where dangerous concentrations of flammable gases, fumes or vapors are continuously present or present for long periods under normal operating conditions. Areas, where dangerous concentrations of flammable gases, fumes or vapors are occasionally present under normal operating conditions. Areas, where dangerous concentrations of flammable gases, fumes or vapors are rarely present or present for short periods under normal operating conditions. IIC (acetylene + hydrogen) IIB (ethylene) IIA (propane) Class I temperature classes NEC T1 ( 450 C ) T2 ( 300 C ) T3 ( 200 C ) T4 ( 135 C ) T5 ( 100 C ) T6 ( 85 C )

26 8/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 5 Amending general safety instructions 5.1 Information on the name plate and the valve solenoid The meaning of the information on the name plate applicable to the non-electrical part of the valve can be seen from the numbered fields of the following table no. Type of information Information or example 1 Manufacturer's logo Rexroth 2 Material number of the valve (= order number) e.g.: MNR: R Type designation complete valve e.g.: 4WE6E6X/EG24VE1Z2 4 Serial number of the valve e.g.: SN: Manufacturer's factory number e.g.: Date of manufacture (year and week) e.g.: FD: 03W01 7 Maximum operating pressure pmax = 350 bar 8 Ambient temperature range 20 C Ta +60 C 9 Hydraulic symbol according to ISO 1219 Graphic 10 Designation of origin Made in Germany 11 Name and address of the manufacturer BOSCH REXROTH AG D LOHR 12 Customer's or production order number e.g.: Customer material number or additional information e.g.: CNR:

27 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 9/20 Please find the meaning of the information on the name plate of the valve solenoid mounted on the valve in the correspondingly numbered fields of the following table no. Type of information Information or example 1 Name / logo of the valve solenoid manufacturer HYDAC ELECTRONIC GMBH 2 Address of the valve solenoid manufacturer Saarbrücken, Hauptstr. 27 Germany 3 Explosion protection mark 4 Internal identification number e.g.: EX USA 5 Nominal voltage e.g.: 24 VDC 6 Rated current e.g.: A 7 Customer material number e.g.: R Mark for protection class according to NEC 505 Class I, Zone 1 AEx e mb IIC T4 Gb 9 FM certificate no Admissible ambient temperature range -20 C Ta +60 C 11 Electrical characteristic values: Duty cycle according to IEC 34-1 (VDE 0580) and frequency e.g.: S1(DB) 12 Serial number of the valve solenoid and date of production e.g.: Protection class according to NEMA 250 Enclosure type 4 14 Application note Cable +100 C 15 Safety instruction WARNING - do not open when energized

28 10/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 5.2 Special residual risks and protective measures WARNING Danger zone Residual risk Protective measure(s), safety instructions Valve Loss of explosion protection due to overheating Observe the prescribed minimum distance in the case of battery assembly of several valves. Observe the prescribed minimum size and minimum heat conductivity of the valve subplate. Make sure that the heat dissipation of the valve is not impeded. See Requirements on the valve subplate. In the case of valves with two solenoids, a maximum of one of the solenoids may be energized at a time. The maximum temperature of the valve casing surface is 115 C. This must be considered when selecting the connection cable or to avoid the connection cable coming into contact with the casing surface. Valve solenoid Risk of burning from hot surfaces Provide for a suitable touch guard. Allow the valve solenoid to cool down to room temperature before touching it directly with your hands during maintenance works. Put on heat-protective gloves before touching it, if necessary Requirements on the valve subplate WARNING Explosion hazard! If the following minimum values are not observed, there is the risk of excessive heating of the valve solenoid and loss of explosion protection. Thermal conductivity: at least 38 W/mK Minimum size L x W x H in case of individual assembly: mm, for recommended subplates, see 12.1 Available accessories Minimum cross-section W H of the manifold in case of bank assembly of several valves: mm Minimum distance between the longitudinal valve axes in the case of bank assembly of several valves: 55 mm Changes at the surface protection of the valve WARNING Explosion hazard! The valve solenoid is equipped with a suitable surface protection at the factory. The valve solenoid must not be painted or otherwise coated with non-conductive substances! Any change at the surface protection of the valve solenoid will lead to loss of the explosion protection! Modifications WARNING Modifications exceeding the extent described in these operating instructions are not permitted Notes on the valve use Observe the following information during the project planning: WARNING During operation, the surface temperature of the valve solenoid exceeds 50 C. Provide for suitable and satisfactory contact protection. Be aware of possible pressure intensification if the valve is connected to the chamber on the piston rod side of a differential cylinder. If the outflow of the hydraulic fluid from this chamber is obstructed, pressure on the cylinder may result in a pressure intensification that may damage cylinder chamber, supply line, and valve. Make sure that there is adequate mechanical protection against any high-pressure water jet that may be used during cleaning work.

29 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 11/20 The simultaneous operation of both solenoids leads to malfunctions, excessive heating and will result in loss of explosion protection. The solenoid coil may only be commissioned if mounted to the valve including pole tube and mounting nut and if the protective earthing conductor and the potential equalization conductor are connected. Corresponding to the rated current, a fuse according to IEC and/or UL has to be connected upstream of every solenoid coil (max. 3 x I nom ). The shut-off threshold of the fuse has to match the prospective short-circuit current of the supply source. The prospective short-circuit current of the supply source may amount to a maximum of 1500 A. This fuse may only be installed outside the explosive area or must be of explosion-proof design. The fuse can be accommodated in the related supply unit or must be separately connected upstream. For information on the recommended pre-fuse see Data sheet, overcurrent fuse and cut-off voltage peak. NOTE To ensure proper functioning, care must be taken that the pressure chamber of the valve solenoid is always filled with hydraulic fluid. Pressure peaks in the joint return line of more than one valve may cause unintended control spool movements and thus unintended switching processes. This applies in particular when valves with detent are used. It is recommended to use separate return lines. If due to the operating conditions to be expected during the switching processes, flows have to be anticipated that exceed the valve's performance limits that can be seen from the characteristic curve, a throttle insert must be used in channel P to limit the flow. The performance limit specified in the data sheet only applies in the case of two flows in opposite directions (e.g. flow from P to A and simultaneous return flow from B to T). Due to the flow forces acting within the valves, the performance limit may be considerably lower in applications with only one flow. With valves with the switching symbol A and B (see data sheet), port T must be used as the leakage oil connection if the operating pressure exceeds the permissible tank pressure. Ports P, A and T with a 3/2 directional valve or ports P, A, B and T with a 4/2 and 4/3 directional valve are clearly assigned according to their function and must not be arbitrarily exchanged or closed. The flow is only permitted in the direction of the arrow specified in the Data sheet. Due to the inductive effect, the switch-off of the valve solenoid results in a voltage peak. The valve solenoid already contains an interference protection circuit dampening these voltage peaks. If necessary, you must, however, provide for additional external circuits in order to prevent the residual voltage peaks from affecting the connected power circuits. The values for the residual voltage peak depend on the valve solenoid used, see the Data sheet Working safely at the valve DANGER Before carrying out any work at the valve, you must first make sure that an explosive atmosphere cannot occur during the period of the work.

30 12/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 6 Assembly and (initial) commissioning 6.1 Safety instructions for assembly and (initial) commissioning DANGER Before any work such as assembly or disassembly is carried out at the valve, the hydraulic system must be depressurized and the electrical control de-energized. In order to avoid dangers from static charges, the mounting or subplate on which the valve is to be fitted must be electrically conductive and included in the potential equalization according to IEC and IEC Rotating the solenoid coil by ± 90 The solenoid coil can be mounted with an offset of ± 90 to the pole tube, i.e. the longitudinal axis of the valve. NOTE The pole tube of the valve solenoid is completely sealed towards the oil circuit. The solenoid coil can therefore still be twisted if the valve has already been installed. When turning the solenoid, make sure that it does not project over the valve connection surface. Make sure that the valve solenoid moves freely and does under no circumstance rest on the base plate to avoid damages to the valve. WARNING Explosion hazard! Strictly observe the modification instructions as improper assembly will result in loss of the explosion protection. 1. Detach the mounting nut of the valve solenoid at the pole tube (hexagon nut, wrench size 32). 2. Remove the solenoid coil and the O-ring from the valve and rotate it by 90 in the desired direction. 3. Re-attach the solenoid coil in the desired position so that the locating pin of the solenoid coil enters the corresponding locating hole of the valve housing. 4. Mount the O-ring to the pole tube and push it to the solenoid coil. 5. Re-tighten the mounting nut of the valve solenoid (hexagon nut, wrench size 32). Tightening torque: Nm 6.3 Assembly WARNING Explosion hazard! Check whether the explosion protection marks on the name plate of the solenoids comply with the information in these operating instructions. Check based on the type designation on the name plate of the valve, based on the information on the name plate of the valve solenoid, whether the valve type is correct. Also check the scope of delivery for completeness and possible transport damage. Also observe the safety instructions in 5.2 Special residual risks and protective measures as well as Notes on the valve use and Working safely at the valve. Check whether the operating instructions for the valve are complete. Contact us if the operating instructions are incomplete. Before any assembly and disassembly work starts, the surroundings must be cleaned so that no dirt can get into the oil circulation system. Only non-linting fabric or special paper may be used for cleaning. 1. Check the valve contact surface for the required surface quality (see Data sheet, unit dimensions ). Remove the protective plate from the valve and keep it safe for returns in case any repairs become necessary later. 2. Check the seal rings at the valve connection surface and possibly for completeness. Other sealants are inadmissible. 3. Put the valve on the valve contact surface. WARNING For reasons of stability only use the valve mounting screws listed in 12.1 Available accessories. Always fasten the valve with all 4 valve mounting screws as otherwise, leak-tightness is not guaranteed. 4. When using the subplates mentioned in 12.1 Available accessories or in case of assembly on comparable cast iron installation surfaces, tighten all four valve mounting screws using a torque power screwdriver (tolerance 10%) and a tightening torque of 7 Nm (5.2 ft-lbs) +/- 10%. This tightening torque refers to the maximum admissible operating pressure. If the valve is to be used at a reduced maximum pressure and in this connection is to be mounted on mounting surfaces of a different material, it might be necessary to use a lower tightening torque in order to rule out any damage.

31 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 13/20 DANGER Check the structure of the valve using the circuit diagrams, device lists and assembly plans. Clarify possible differences with the responsible persons. 5. Make sure that pipes and/or hoses are connected to all ports and/or that the ports are closed with plug screws. 6. Carry out a special check to make sure that the cap nuts and flanges are correctly tightened at the pipe fittings and flanges. NOTE Mark all checked fittings, e.g. using a permanent marker. 7. Make sure that all pipes and hose lines and every combination of connection pieces, couplings or connection points with hoses or pipes are checked for their operational safety by a person with appropriate knowledge and experience. 6.4 Establishing the electrical connection CAUTION Connection lines for valve solenoids with a terminal box may only be connected by or under the supervision of a specialized electrician. De-energize the connection line prior to assembly. Use fine-wired conductors with pressed-on wire end sleeves only. Strip the wires of the connection lines and the protective grounding conductor with mm. Strip the wires of the external equipotential bonding with mm. Use only lines satisfying the requirements on the terminal areas of the connection terminals, see data sheet. The maximum temperature of the valve casing surface is 125 C. This must be considered when selecting the connection cables or to prevent the connection cable from coming into contact with the casing surface. Connect the protective earthing conductor and the earthing correctly. Avoid sharp bends in connection lines and litz wires to prevent short-circuits and interruptions. When using a finely stranded conductor, equip it with wire end ferrules. The lines that are used must be suitable for -20 C to +100 C. All types have to be equipped with an internal protective grounding conductor terminal and an external grounding terminal. At the factory, the valve is fitted with an adapter for a cable entry and it guarantees type 4 according to protection class NEMA 250. The cable entry is provided by the customer and also has to comply with type 4 according to protection class NEMA 250. Adapter connection data: Internal connection thread NOTE 1/2" NPT When mounting the customer's cable entry, the adapter is to be held in place with a suitable tool (hexagon wrench, wrench size 27). The connection is polarity-independent. In case of a valve solenoid to be connected to AC voltage, a bridge rectifier is integrated in the valve solenoid. 1. Open the terminal box (internal hexagon, wrench size 3). 2. Guide the cable through the adapter into the terminal box. 3. Connect the wires of the connection line to the 2 pin connection terminal and the internal protective grounding conductor terminal. 4. Make a connection to the external equipotential bonding line. Tightening torques for the clamping screws: Operating voltage connection Connection for protective earthing conductor Connection for potential equalization conductor Nm Nm Nm 5. Assemble the cover with the seal beneath it. Tighten the mounting screws (internal hexagon, wrench size 3) with spring washers diagonally, one after the other. Tightening torque of the cover screws: Nm.

32 14/20 Bosch Rexroth AG Hydraulics WE...VE1... RE VE1-B2 Assemble the cable guide on the opposite side of the terminal box: CAUTION The adapter 1/2" NPT may only be modified when the solenoid coil is disassembled. 1. Disassemble the solenoid coil, see 6.2 Turning the solenoid coil by ± Open the terminal box (internal hexagon, wrench size 3). 3. Remove the blind plug (hexagon, wrench size 22). 4. Disassemble the adapter (hexagon, wrench size 27). 5. Install the adapter on the opposite side, tightening torque Nm. 6. Mount the blind plug, tightening torque Nm. 7. Assemble the solenoid coil, see 6.2 Turning the solenoid coil by 90 C. 6.5 Initial commissioning, re-commissioning Bleeding the hydraulic system NOTE Observe the operating instructions of the device and/or system into which the valve is installed. 1. Switch the valve several times under operating pressure before placing it into full operation. This will press out any remaining air from the valve. Thus, mechanical damage being caused by inadmissibly high acceleration of the fluid and the control spool is avoided and the life cycle of the valve is extended. NOTE You can also achieve the switching movement of the control spool necessary for the bleeding procedure by manually actuating the manual override. For further information, see 8.1 Operating the optional manual override Performing a leak test Check whether during operation, hydraulic fluid leaks at the valve or at the connections Checking electrical connections / replacing seals Electrical connections must be checked for proper condition by or under the guidance and supervision of a specialized electrician before the initial or any recommissioning. Seals are subject to a natural process of aging and for this reason, check seals for damages every time the terminal box is opened and replace them if required. This check has to be carried out every 3 years from the date of manufacture of the valve. For order details for seal kits, please refer to 11.3 Available spare parts. 7 Disassembly DANGER Before disassembly, ensure that the hydraulic system is depressurized and that the electrical control system is de-energized. 1. Loosen the electrical connections professionally. 2. Prepare a container for collecting the escaping hydraulic fluid. 3. Only loosen the valve mounting screws using a suitable tool. 4. Remove the valve mounting screws and loosen the valve from the valve contact surface. 5. Collect the escaping hydraulic fluid in the provided container and dispose of it properly. 6. If the valve is to be returned to the manufacturer for repair, close the valve connection surface using the protective plate supplied or protect it using equivalent packaging in order to avoid contamination and damage. 7. Seal the subplate in order to avoid contamination.

33 RE VE1-B2 WE...VE1... Hydraulics Bosch Rexroth AG 15/20 8 Operation 8.1 Operating the optional manual override Valves of type WE...VE1... are equipped with a manual override. Using this manual override, the switching function of the valve can also be triggered if the valve solenoid is not energized. The manual override is only intended for manual operation. The manual override is located on the side of the valve solenoid facing away from the valve. NOTE With WE...VE1... directional valves, the manual override is only sensible if the pressure in the tank channel of the valve does not exceed 50 bar. Above this pressure value, the actuating force that is to be applied is too large and there is a risk of injury if the tool slips. DANGER Only operate the manual override if it is ensured that this will not trigger any dangerous working movement of the connected actuator! CAUTION Do not use sharp-edged tools to operate the manual override! There is the risk of damaging sealing surfaces at the valve solenoid. The manual override is only intended for short-time manual actuation 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!