Rexroth Manual for Actuators

7/22/2019 Rexroth Manual for Actuators

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Bosch Rexroth AGIndustrial HydraulicsHydraulics for Energy Technology, Turbine Control

Zum Eisengieer 1

97816 Lohr am MainGERMANY

PARICHHA

BHARAT HEAVY ELECTRICALS LTD.

BHEL Purchase Order No. 71956/B8V6033

Rexroth Sales Order No. 900005


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reg. naming data sheet

EHA4 - actuators PARICHHA

1 Operating instructions

EC Declaration by the manufacturer

2 Connection diagram HS-A11-N680

3 Circuit diagram HS-A11-N674

4 Parts list UH01-08004-5313-B

5 Actuator drawing CGE1MF3... D901272CGE1MF3... D901273CGE1MF3... D901274

CGE1MF3... D901275

6 2- way cartridge valves

type: LC32 A40E7X/Vtype: LFA 32 WEA27-7X/V

RE 21010

7 3/2 and 4/2- way directional poppet valves with solenoidoperation

type: M-3SEW 6 C3X/420MG24N9Z2/B08V SO864type: M-3SEW 6 U3X/420MG24N9K4/V

RE 22058

8 Servo directional valve in 4- way design

type: 4WS2EM10-5X/60B11T315K31CV-114

RE 29583

9 High pressure filters

type: DFP W 060 QB 25BM1.X/-V-Wtype: DFP BH/HC 060 QB 10BM1.X/-V-W

mfr Fa. Hydac

10 Transsonar transducer

type: BTL5-E10-M-0100-K-K02type: BTL5-E10-M-0150-K-K02

mfr Fa.Balluff

11 Sales and service network RDE 02000


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IndustrialHydraulics

Electric Drivesand Controls

Linear Motion andAssembly Technologies Pneumatics

ServiceAutomation

MobileHydraulics

Electrohydraulic Actuator - Steam

Type: CGE1...2X/... ; CXE12x/Operating Instructions


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2 / 45 cce_antriebe-dt-cxe1-2x_bal_v10_en

These instructions must be read and applied by everybody who isentrusted with work on the actuator:

In particular, you have to read and observe the safety regulations inchapter 3.

A copy of these instructions must always be available in the vicinityof the electrohydraulic actuator.

Bosch Rexroth AG

Industrial Hydraulics

Systems & Engineering

Zum Eisengieer 1

D-97816 Lohr am Main

Tel.: +49 (0) 9352/18-1178FAX: +49 (0) 9352/18-1054

CCE_ANTRIEBE-DT-CXE1-2X_BAL_V10_DE.doc

07.06.

Bosch Rexroth AG 2006

The contents of this brochure must not be handed over whetherin whole or in part - to third parties without the written permissionby Bosch Rexroth. All technical data, drawings, etc. are subject tocopyright laws.

Publisher

Document no.

Date of issue

Copyright


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Contents

cce_antriebe-dt-cxe1-2x_bal_v10_en 3 / 45

Table of contents

1 Identification of the product.....................................................................................61.1 Verifying the consignment..................................................................................6

Scope ..............................................................................................................................6Condition when supplied .................................................................................................6

1.2 Identifying the electrohydraulic actuator.............................................................7Nameplate.......................................................................................................................7

1.3 Use according to the intended purpose .............................................................71.4 Wrongful use......................................................................................................8

2 Product documentation ............................................................................................92.1 About the operating Instructions ........................................................................ 9

Signs and symbols used .................................................................................................9Safety and warning notes..............................................................................................10

2.2 Technical drawings ..........................................................................................112.3 Parts list / spare parts list.................................................................................11

3 General safety regulations .....................................................................................133.1 General principles............................................................................................133.2 Important notes on the installation ...................................................................143.3 Safety during operation....................................................................................143.4 Working on the electrohydraulic actuator.........................................................14

Qualification of personnel..............................................................................................14Personal protective equipment......................................................................................15Installation, maintenance, repair ...................................................................................15

3.5 Structural modifications....................................................................................173.6 Residual risks arising out of the electrohydraulic actuator ...............................17

4 Technical description .............................................................................................19


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Inhalt

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4.1 Fields of application .........................................................................................194.2 Electrohydraulic actuator .................................................................................19

Components The schematic structure of an electrohydraulic actuator with its mostimportant components is shown on Fig. 4.1..................................................................19Function of control actuator and trip actuator................................................................21

5 Transport and storage ............................................................................................245.1 Storing / preserving electrohydraulic actuators ................................................ 24

Type of storing...............................................................................................................24Type of preservation......................................................................................................24

5.2 Lifting and transporting electrohydraulic actuators...........................................25Weight data The weight of the electrohydraulic actuator can be found on, amongothers, the installation drawing......................................................................................25Lifting gear and lifting accessories/lifting points ............................................................25

6 Installation and commissioning.............................................................................286.1 Preparations for installation..............................................................................286.2 Mounting the electrohydraulic actuator to the valve.........................................29

Mounting, aligning and fitting the actuator to the lantern. ...........................................29

6.3 Connecting the electrohydraulic actuator to the pressure line..........................306.4 Making the electrical connections of the electrohydraulic actuator ..................316.5 Commissioning the electrohydraulic actuator...................................................32

7 Operation .................................................................................................................357.1 Normal operation .............................................................................................35

8 Inspection and maintenance work.........................................................................378.1 General ............................................................................................................378.2 Inspection and maintenance schedule.............................................................398.3 Maintenance work on the electrohydraulic actuator .........................................41

9 Service addresses...................................................................................................439.1 Service points in Europe ..................................................................................43


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Contents


9.2 Service points in America.................................................................................439.3 Service points in Asia.......................................................................................43

10 Waste disposal ........................................................................................................44Own notes


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1 Identification of the product

6 / 45 CCE_ANTRIEBE-DT-CXE1-2X_BAL_V10_EN.doc


These operating instructions are valid for electrohydraulic

actuators of types"CGE1 2X /and CXE1...2X/...", manufactured by.Bosch Rexroth AG, Lohr am Main.

1.1 Verifying the consignment

Scope

Before mounting the electrohydraulic actuator to the valve, you

have to verify that the following parts are included in the transportpackaging:

Electrohydraulic actuator

Accessories according to packing list

Provision of documentation

If contractually agreed, the documentation and operating in-structions are delivered separately on a CD. If no separatedelivery on a CD was agreed, the documentation and the

operating instructions are delivered together with the actua-tor.

Documentation:

Scope according to table of contents

Condition when supplied

Depending on the variant ordered, the electrohydraulic actuator isshipped with the piston rod retracted or extended the limit stop byspring force. The relevant version is given in the type designation

or on the installation drawing.When shipped, the electrohydraulic actuator contains a residualamount of hydraulic oil.

Any accessory parts supplied according to the packing list are in-stalled or must be mounted by you to the electrohydraulic actuator.

A nameplate is attached to the actuators housing. It shows theexact type designation, the serial number/job order number andother important data.

Compare the serial number/job order number on the nameplate

with the serial number/job order number on the test report, which is

Check compliance ofthe delivered parts


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Identification of the product 1


attached as Annex to these operating instructions (see chapter 1and documentation).

Inform Bosch Rexroth immediately, if

the consignment is not complete the delivered items deviate from the delivery note or the packing

list

the details on the nameplate differ from those given on the tech-nical drawing or the parts list

the serial number/job order number specified on the electrohy-draulic actuator differs from the number indicated in the test re-port.

Operating instructions, technical drawings, test reports and partslists must always be kept together.

1.2 Identifying the electrohydraulic actuator

Nameplate

Electrohydraulic actuators of types " CGE1...2X/... (extending) and CXE12X/ (retracting)can be clearly identified with the help of the nameplate.

1.3 Use according to the intended purpose

These electrohydraulic actuators serve as control or trip actuatorsfor control or trip valves on steam turbines.

They may only be used:

at places of operation, for which the design of the electrohy-draulic actuator is suitable

with the forces (on the spring package) described in the manu-facturers documents

at temperatures specified in the manufacturers documents

in rooms, for which they are suitable

in conjunction with valves for which the electrohydraulic actua-tor is rated according to the technical planning.


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1.4 Wrongful use

Any application that does not comply with the specifications is re-

garded as wrongful use.

This includes:

Places of operation, for which the electrohydraulic actuator wasnot designed

Forces (on the spring package) which do not correspond to thespecified requirements

Temperatures other than those specified in the manufacturersdocuments

Valves for which the electrohydraulic actuator is not rated ac-cording to the technical planning.

Wrongful use can result in personal injury of the operator or thirdparties. Moreover, the electrohydraulic actuator itself or other prop-erty may be damaged.


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Product documentation 2


2 Product documentation

The following documents accompany the electrohydraulic actuator:

Scope according to table of contents

2.1 About the operating Instructions

The operating instructions include important notes on the safe andproper operation of the electrohydraulic actuator. Observing thesenotes helps to:

avoid risks

reduce repair and downtime costs

increase the reliability and service life of the actuator

The operating instructions include information about

Installation / removal

Operation

Maintenance

Repair

Transport

Waste disposal

Signs and symbols used

The text following this sign describes activities that must usuallybe carried out in the given order.

The text following this symbol describes the result of an action.

Note: After the introducing word "Note" you will find notes anduseful tips on the optimum use of the electrohydraulicactuator.


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Safety and warning notes

Special safety regulations may become applicable for the individualwork to be carried out. These safety notes can be found in the op-

erating instructions for the relevant activity. They are clearly high-lighted with a warning sign (pictogram). Depending on the degreeof hazard, various signal words are used.

Signalword

Possible consequences, if safety note is not observed:

DANGER Death or severest injuries!

WARNING Death or severest injuries are possible!

CAUTION Light or minor injuries!

NOTE Material damage to the electrohydraulic actuator or the sur-roundings!

Table 2.1: Signal words and their use

Special safety notes are provided at the relevant locations. Theyare identified with the following symbols.

General hazard

This symbol refers to activities, which involve a risk of general per-sonal injury.

Risk of bruising

This symbol refers to activities, which involve the risk of bruising bytrapping fingers or hands

Suspended loads

This symbol refers to activities, where suspended load could falldown cause personal injury.

Damage to property

This symbol refers to activities, which involve the risk of compre-hensive damage to property.

Warning symbols


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Product documentation 2


2.2 Technical drawings

The following technical drawings are included in the scope of sup-ply:

Installation drawing with dimensional data

The electrohydraulic actuator is shown completely on the instal-lation drawing. It includes all details with regard to dimensions,weights and technical data of the actuator. All dimensions arereferred to the system zero position (valve closed) of the ac-tuator. These dimensions can differ from the condition as sup-plied (actuator completely retracted or extended).

Hydraulic circuit diagram

The hydraulic circuit diagram explains the operating principle ofthe electrohydraulic actuator.

The specified item numbers are explained in the associatedparts list.

Terminal diagram

The terminal diagram explains the terminal assignment in theterminal box.

Spare parts list

(see section 2.3)

2.3 Parts list / spare parts list

The parts list is a separate list that accompanies the electrohydrau-lic actuator.It lists the components used for the relevant electrohydraulic actua-tor.

Spare components can be ordered according to the spare parts list.We recommend that corresponding spare parts be kept in stock.


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Own notes


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General safety regulations 3


3 General safety regulations

This chapter contains a summary of all important safety regula-

tions.

Everybody who is put in charge of carrying out work on theelectrohydraulic actuator must read and observe this chapter.

3.1 General principles

This electrohydraulic actuator was designed according to state ofthe art and recognized safety rules. The use of the hydraulic sys-

tem can nevertheless result in risks to life and limb of the user orthird parties or comprehensive damage to property, if:

the electrohydraulic actuator is not used according to the in-tended purpose

the electrohydraulic actuator is unauthorizedly changed ormodified

safety regulations and safety notes are not observed.

Operate the system only when it is in technically perfect conditionand in accordance with the intended use, being aware of safetyand risks and observing the present operating conditions!

Bosch Rexroth issued an EC manufacturers declaration in thesense of Directive 98/37/EC.The manufacturer declares that the supplied components / assem-blies were manufactured in accordance with applicable harmonizedstandards/specifications.Commissioning of these components / assemblies is prohibiteduntil it was established that the machine, into which these compo-nents / assembles are to be integrated, comply with the stipulationsof the EC Directive.


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3.2 Important notes on the installation

Ensure adherence to the maximum hydraulic pressure for the elec-trohydraulic actuator by taking suitable measures (e. g. pressurerelief valves).

Provide equipotential bonding!

3.3 Safety during operation

When the electrohydraulic actuator is ready for operation, do notreach into the area of the piston rod or the area, in which the actua-tor can be coupled to a steam valve! The operation of the driveinvolves a risk of injury by bruising fingers!

Never apply a hydraulic pressure to the electrohydraulic cylinderthat is higher than the permissible maximum operating pressureindicated on the electrohydraulic actuator: see installation drawing

Since hot media are transported in the system, do not touch the

electrohydraulic actuator! Risk of hand burns! If the cylinder bodyor attached parts must be touched, use heat-resistant protectivegloves!

Plug-in connections (e. g. connector sockets) may only be pluggedor unplugged when the system is disconnected from the powersupply!

3.4 Working on the electrohydraulic actuator

Qualification of personnel

Installation, maintenance, repair and troubleshooting require spe-cial knowledge and may only be carried out by qualified and spe-cifically trained personnel who are authorized to carry this work out!

Work on electrical equipment may only be carried out by anelectrical specialist or by instructed persons under the supervi-

Installation,maintenance and repair


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sion of an electrical specialist in accordance with electrotechni-cal rules.

Electrical specialists are persons who, due to their professionaltraining, knowledge and experience and knowledge of relevant

regulations can assess the work assigned to them, can recog-nize possible risks and take suitable precautionary measures.

Work on hydraulic componentsmay only be carried out byspecialist personnel having specific knowledge and experiencein the field of hydraulics!

Transport, assembly, installation, commissioning and waste dis-posal may only be carried out by assigned specialists.

Personal protective equipment

If required, wear suitable personal protective equipment when car-rying out work, e. g. protective gloves, helmet, protective clothing,protective goggles, safety shoes, etc.!

Installation, maintenance, repair

If work is carried out that is not authorized by Bosch Rexroththe warranty will become void!

Repairs may only be carried out by specialists of the manufac-turer! Before devices or components are opened, these andthe complete electrohydraulic actuator must be de-energized,depressurized and secured against restarting.

Servicing (maintenance and repair) on an electrohydraulic actuatorthat is installed in a system may only be carried out, if this was ex-pressly permitted by responsible persons!

Before carrying out work, depressurize system sections and pres-sure lines that are to be disconnected and let the medium drain!

Work on electrical components may only be carried out while thesystem is disconnected from the power supply.

Before installing or removing electrical connections, the latter mustbe disconnected from the power supply!

Plug-in connections: DO NOT DISCONNECT WHILE ENER-GIZED!

Transport, assembly,installation,

commissioning, wastedisposal

Before carrying outwork


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If it is required to remove protective guards or safety equipment formaintenance and repair work, these items have to be refitted andtheir function checked immediately after completion of the mainte-nance and repair work.

Before working on the electrohydraulic actuator, make sure that theactuator is disconnected from the hydraulic supply!

Let components of the electrohydraulic actuator cool down! If it isrequired to touch the electrohydraulic actuator, wear heat-resistantgloves!

Secure the electrohydraulic actuator against undesirable pressuri-zation or energization.

When transporting or removing the electrohydraulic actuator, neverstay under a suspended load.

Use lifting gear and tooling skillfully.

Use only suitable lifting gear and lifting accessories that can relia-bly hold the weight of the load!

Install and mount hydraulic lines properly. Do not mix up connec-tions! The length and quality of lines must meet the requirements.Only welded cone fittings or forming fitting systems with soft sealsand flanges are permitted.

The use of cutting ring fittings or hydraulic hoses is not per-mitted!

The springs on the electrohydraulic actuator are pretensioned. Riskof injury! The housing with integrated manifold may only be openedby specialists of the manufacturer using special accessories.

Spare parts must meet the technical requirements laid down by themanufacturer. This is ensured when genuine spare parts are used.Only genuine spare parts may therefore be used!

Always keep the warning signs on the electrohydraulic actuatorlegible! Replace damaged and illegible signs.

Strictly adhere to the maintenance and inspection intervals pre-scribed in these operating instructions and document any mainte-nance and inspections carried out.

When handling oils, greases or other chemical substances, ob-serve the safety instructions valid for the relevant product!

Never use benzene or other, easily inflammable substances for

cleaning!

While carrying outwork


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Do not use linty cleaning cloths!

Immediately after completion of maintenance and repair work anyremoved protective guards or safety equipment must be refittedand their function checked.

During commissioning, inspect the electrohydraulic actuator forleakage, loose connections and visible external damage. Immedi-ately rectify any detected defect!

Ensure a safe and environmentally compatible disposal of con-sumables, auxiliary materials or spilled fluids! Dispose of hazard-ous materials in accordance with their applicable operating instruc-tions!

After completion of any work, check all connections and fittings for

leakage.

After completion of all work, check the fittings on all components forproper fit.

3.5 Structural modifications

Unauthorized modifications on the electrohydraulic actuator are notpermitted for safety reasons.

Moreover, for reasons of compliance with EMC, no changes maybe carried out on the electrical installation (cables, connections,shield).

The parts and components used were specifically designed for thiselectrohydraulic actuator. We expressly point out that parts andspecial equipment that are not delivered by us are not approved byus. The installation and/or use of such products can impair safety.

3.6 Residual risks arising out of the electrohydraulic actuator

Risk of accident during transport, installation and removal of theelectrohydraulic actuator due to uncontrolled movements (e.g. fal-ling down) during lifting. Observe common safety regulations andregulations for the prevention of accidents!

Risk of injury due to contact with hot media or toxic vapors.

Risk of injury due to unintended retracting or extending of the pis-

ton rod opening/closing of the valve during commissioning,maintenance, repair or operation.

After work


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Injury caused by bruising of fingers and hands, if these are caughtbetween the electrohydraulic actuator and the valve during lower-ing. General risk of bruising when installing or removing the actua-tor from the valve.

Risk of scalding when hot oil gets into contact with the skin whenthe electrohydraulic actuator is uninstalled.

Risk of burning on hot solenoids during operation.

Work on the electrohydraulic actuator may only be carried out withsufficient lighting.

Environmental risks due to leaky points on the electrohydraulicactuator when substances that are toxic or harmful to the environ-ment escape (e.g. hydraulic oil, HFD phosphate ester) and get intothe soil or groundwater.

Risk of accident or damage to the environment when residualamounts of oil drain during the installation and removal of the elec-trohydraulic actuator.

WARNING: The electrohydraulic actuator includes a pretensionedspring package. Sudden releasing of the spring package duringremoval can lead to severest injury or death!Caution! The maintenance intervals must be observed. Duringmaintenance, warning signs must be checked, cleaned and, if re-

quired, replaced. For the installation and removal of the actuator,special tools and qualified specialists are required. The manufac-turer must in any case be contacted.

Electrical shock! Cabling work may only be carried out bytrained electrical specialists observing common safety regula-tions.

Caution:

Incorrect connections can result in destruction of the valuable elec-tronics or in uncontrolled movements in conjunction with an acti-

vated hydraulic system. The closed control loops may only be put into operation by spe-

cialist personnel with the relevant qualification.

Incorrect connections can result in excessive housing voltage andhigh discharge currents.

Danger to life due to shock currents

Risk of injury due to electrical shock

Risk of injury due to burning


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Technical description 4


4 Technical description

4.1 Fields of application

Electrohydraulic actuators of types "CGE1 2X /andCXE1...2X/..." are used as control or trip actuators for control ortrip valves on steam turbines.

4.2 Electrohydraulic actuator

Electrohydraulic actuators are cylinders and include a pretensionedspring package. They belong to the family of double rod cylinders.The direction of action of the spring is always towards valve clos-ing (mech. failsafe).The electrohydraulic actuator is mounted to the valve to ensurecompleteley tight closing of the valve when no hydraulic pressure isapplied.

Components The schematic structure of an electrohydraulic actuator with itsmost important components is shown on Fig. 4.1.

Fig. 4.1: Components of the electrohydraulic actuator (the exemplary illustration shows a trip actuator)


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Electrohydraulic actuators are designed as double rod cylinders. Acoupling half is provided at the end of the piston rod. The actuatoris fitted with two separate pipe connections for pressure X1 (P) andtank X2 (T) on the housing with integrated manifold.

The actuator is hydraulically controlled via the housing. This hous-ing includes all the functions required for controlling the actuator.

The actuators comprise a spring column consisting of disk springsthat are made up to form a package. The spring package is ratedaccording to customer specifications. The package is located in thefront part of the cylinder and ensures reliable closing (of the valve)in the event of a pressure failure.The spring column is protected against external influences by a

protective tube. Condensate that may enter the housing is largelydischarged by special constructive features. Additional precautionsagainst the ingress of humidity and steam must be taken by thecustomer.

An anti-rotation feature is not provided for this actuator version.

The electrohydraulic actuator is connected to the valve by meansof the coupling half fitted. The mating piece must be provided bythe customer.

2 lifting points are fitted to the housing of the electrohydraulic ac-

tuator and 4 additional lifting points on the flange, which are ratedaccording to the weight of the actuator.The actuator can be lifted and transported at these lifting pointsusing suitable lifting gear.

Position transducers signal the position of the piston rod to theopen/closed-loop control. The aperture of the valve can be deter-mined on the basis of the piston position. For the position trans-ducers used, see parts list. More detailed information can be foundin the operating instructions for the position transducers.

The limit switches indicate the position of the cylinder piston at an

upper and/or lower end point

More detailed information about optionally installed limit switchescan be found in the parts list and the description of the limit swit-ches.

Actuator

Hydraulic control

Spring column

Anti-rotation feature

Coupling

Lifting points

Position transducers

Limit switches

(optional)


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Function of control actuator and trip actuator

The electrohydraulic actuator consists of an actuating cylinder, thedisk plate column directly fitted, the built-on hydraulic control and

integrated or attached position transducers.

The pilot oil is supplied externally from a central supply unit.

Electric power is supplied and signals are transmitted via a terminalbox.

The actuator consists of a double rod cylinder.

In the opening direction of the steam valve, the piston rod is movedin the cylinder housing by hydraulic pressurization. At the sametime, the spring column is tensioned. In the closing direction of the

steam valve, the piston rod is moved exclusively by spring force.The incurring fluid is fed from the pressure chamber through inter-nal pipes in the cylinder housing into the tank chamber.

Position transducers (ultrasonic or inductive) as well as optionallimit switches are integrated or attached for position sensing. Theconnection to the central pilot oil supply is established through twoseparate pipe connections for pressure X1 (P) and tank X2 (T).

Depending on the version, the hydraulic control integrated in thecylinder housing includes

a servo-valve of special design (two or three coils and trimmed)

for closed-loop controlling or

a directional valve for starting up the valve for the trip function.

To prevent the ingress of dirt, an additional filter is installed in thepilot oil supply of the servo-valve for pressure port X1 (P) of thecontrol actuator. Moreover, the control actuator and the trip actua-tor are fitted with a further filter to prevent spontaneous failurecaused by coarse contamination in the hydraulic medium.

Control and trip actuators are both provided with a superimposedtrip function. The relevant version is given on the circuit diagram.All control parts are connected via internal channels in the housing

with the cylinder chambers (no pipes).

General

Actuators

Hydraulic control


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For the controlactuator,closed-loop controlling is performed bymeans of the servo-valve which is controlled on the basis of acommand value provided by the controller. The actual value is con-tinuously verified with the help of the position transducer of the ac-tuator in a command/actual value comparison. The associated con-trol and instrumentation technology must be provided by the cus-tomer.

For the trip actuator,controlling is performed by means of the di-rectional valve, which is energized or de-energized for slow open-ing or closing of the associated valve during normal starting orstopping of the system.

In the event of turbine emergency tripping, the directional valves,which operate according to the closed-circuit current principle, arede-energized to initiate emergency tripping.

The actuating time of the actuator in the closing direction is deter-mined by VM orifice(s) .

The permissible closing speed shortly before the end position ofthe steam valve is reached is ensured by hydraulic damping. It isdetermined by a VD orifice.

Further information can be found on the enclosed hydraulic circuitdiagram.

Operating principle


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Own notes


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5 Transport and storage



5.1 Storing / preserving electrohydraulic actuators

Type of storing

The electrohydraulic actuators must be stored as follows:

Do not store in the open air, but under a roof or in a well venti-lated room. Do not expose electrohydraulic actuators to sun-light.

Protect them against rising damp: Store them on a shelf or on a

wooden pallet. Cover them with a foil to protect them against dirt and dust.

All ports of the electrohydraulic actuator must be properly plug-ged.

After the transport packaging was opened, it must be properlyre-closed for storing.

Provide an oil drip tray under the place of storage, becauseelectrohydraulic actuators are always shipped with differentamounts of residual oil.

Leave sufficient space between the individual electrohydraulicactuators.

With regard to the storage time, the following must be observed:

Longer than 1 year.

Renew internal and external preservation

Longer than 2 years.

Additional functional test required

Type of preservation

With regard to preservation, we have to distinguish between inter-nal and external preservation (corrosion protection).

The electrohydraulic actuators are dispatched with a partial fill(walls and internal parts wetted with test fluid). This means thatinternal preservation is maintained by the test oil in the cylinder aslong as the cylinder remains airtight closed.

Note: Rests of the protective agents may only be present inthe hydraulic fluid up to a maximum concentration of0.1 %.

Internal preservation


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Transport and storage 5


Further information with regard to internal preservation can be ob-tained from the manufacturer, if required.

The following is valid for external preservation of the electrohydrau-lic actuators:

External preservation is applied in the form of coating sub-stances according to the customers specifications.

In the case of a storing period of more than six months, a corre-sponding finish coating must be applied. The selection of thecoating system (single- or 2-component system) depends onthe substances that attack the protective surface.

Further information with regard to external preservation can be ob-tained from the manufacturer, if required.

5.2 Lifting and transporting electrohydraulic actuators

The packaging of electrohydraulic actuators depends on the size ofthe cylinder. They are delivered in boxes on pallets. The consign-ment must be secured during transport.

Notes are provided on the packaging

with regard to lifting of the load (lifting points and weight)

to indicate the top and bottom of the packaging

Weight data The weight of the electrohydraulic actuator can be found on,among others, the installation drawing.

Lifting gear and lifting accessories/lifting points

Depending on the place of installation and the weight of the elec-trohydraulic actuator, suitable lifting gear and lifting accessoriesmust be selected and made available (e. g. crane, forklift truck,rope, belt).

Use only lifting gear and lifting accessories that can reliably holdthe weight of the load!

External preservation


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If maintenance work is to be carried out or the actuator uninstalled,the lifting accessories must be checked, among others, for corro-sion and proper fit of the screws, etc.

How to lift the electrohydraulic actuator by means of a crane:

Fix the rope or lifting belt to the lifting points of the actuator.Take note of the maximum load carrying capacity of the liftingpoints. Make sure that the transport bolts and lifting accesso-ries fit properly and check them for corrosion.

NOTE!Risk of damage to the electrohydraulic actuator, if it is liftedtogether with the valve!

Lift or transport the actuator only at the lifting points.

Make sure that no attachments or cables get jammed.

Lift the electrohydraulic actuator carefully.

Observe valid safety regulations and the regulations for theprevention of accidents.

WARNING!

Suspended loads!

Death or severest injuries, if persons are hit by falling loads.

Never stay under suspended loads!

Use only suitable lifting gear and lifting accessories that canreliably hold the weight of the load!

Wear protective equipment (helmet, safety shoes)!

Now you can carefully transport the electrohydraulic actuator tothe place of installation: During transport, protect the electrohy-draulic actuator against impacts and percussion.


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Transport and storage 5


Own notes


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6 Installation and commissioning



6.1 Preparations for installation

How to prepare the installation of the electrohydraulic actua-tor:

Have the technical drawing and the hydraulic circuit diagram athand: Check whether the type designation and serial num-ber/job order number are identical on the nameplate and on thedrawings.

Place tools and aids ready.

Carefully lift the electrohydraulic actuator from its transport pa-ckaging.

Check, whether all accessories are available.

Mount the accessories, unless they were fitted by the manufac-turer.

Information on how to mount accessory items can be found inthe relevant instructions.

Clean the mounting faces:

The mounting faces must be thoroughly cleaned. Check, whether all fittings on the electrohydraulic actuator are

properly tightened.

Now you can start to mount the electrohydraulic actuator.

Note: Transport brackets and bolts must be kept (in casethe actuator must be returned). If required, consult themanufacturer.


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Installation and commissioning 6


6.2 Mounting the electrohydraulic actuator to the valve

Mounting, aligning and fitting the actuator to the lantern.

The electrohydraulic actuator must be installed in the speci-fied installation orientation, with the piston rod and the valvescrew having to be aligned.

This version of the electrohydraulic actuator can and may onlybe installed according to the installation, coupling and ad-justment instructions of the customer (e. g. turbine manufac-

turer).

The installation, coupling and adjustment may only be carriedout by the manufacturer or specialists specifically trained bythe manufacturer (e. g. turbine manufacturer).

NOTE!

- Damage to property, if the electrohydraulic actuator isinstalled without being correctly aligned!

- Observe correct dimensioning of bolts!

- Adhere to minimum pretension forces (see also installa-tion drawing)

Installation of the extending version of the actuator:

Mount the coupling part provided by the customer to the valvescrew and align it to the actuator coupling according to the in-stallation instructions of the turbine manufacturer.

Insert actuator into seat/fixture.

Tighten the bolts of the flange evenly (cross-wise) while furthertensioning the spring.

This ensures that the actuator is mounted to the valve and, atthe same time, brought from the stroke end position (see over-stroke) to the system 0 position (valve closed).

Tighten the bolts on the coupling.

Observe the tightening torques given in the installation instruc-tions of the turbine manufacturer.

Mechanical mounting to the valve is now completed.


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Installation of the retracting version of the actuator:

Mount the coupling part provided by the customer to the valvescrew and align it to the actuator coupling according to the in-stallation instructions of the turbine manufacturer.

Insert actuator into seat/fixture and screw it on.

Tighten the bolts of the coupling evenly (cross-wise) while fur-ther tensioning the spring.

This ensures that the actuator is brought from the stroke endposition (see overstroke) to the system 0 position (valveclosed).

Observe the tightening torques given in the installation instruc-

tions of the turbine manufacturer. Mechanical mounting to the valve is now completed.

6.3 Connecting the electrohydraulic actuator to the pressureline

When connecting the electrohydraulic actuator to the pressure line,take care that the connections on the actuator housing are not in-terchanged.

NOTE!Before operating the electrohydraulic actuator for the firsttime, clean the pipes!

Foreign particles could get into the cylinder chambers, damageseals or valves and thus cause malfunction.

The actuator may only be connected, if the supply lines are clean.

Hydraulic fluid: Mineral oil (HL, HLP) to DIN 51524 orFire-resistant fluid (HFDR)depending on version

Max. permissible degree of contamination of the hydraulic

fluid to ISO / DIN 4406 (C): 18 / 16 / 13

Note: The supply lines must be flushed for cleaning. (seeseparate flushing procedure)


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During flushing or while pressure tests are being carried out,nobody is allowed to stay in the vicinity of the actuator,If necessary, take suitable precautions.

How to connect the electrohydraulic actuator to the hydraulicpipes:

Connect the ports on the actuator with the corresponding hy-draulic pipes.

Note: Pressure port: X1( P)Tank port: X2 (T)

Tighten the connections according to the valid instructions.

The electrohydraulic actuator is now connected to the hydraulic

pipes. You can pressurize the actuator.

6.4 Making the electrical connections of the electrohydraulicactuator

The electrical connections are established exclusively on the fac-tory-installed terminal box.

The electrohydraulic actuator comes with a mounted terminal box,onto which all electrical components of the electrohydraulic actua-tor were wired by Bosch Rexroth.

After transport, all plug-in connections and terminal connectionsmust be inspected for proper fit and reliable contacting. Check theexisting terminal connection diagram and the available machinedocumentation or plant documentation for plausibility. Or: The ter-minal connection diagram provided by the client and the availablemachine or plant documentation must be checked for plausibilityand observed.

The terminals are suitable for connecting copper wires of havingcross-section of 0.2 to 2.5 mm2.Other cable cross-section or otherconductor material must not be used. Select suitable conductorcross-sections!

The cable material must be appropriate for the ambient conditions.The cable sheath must be resistant to the foreseeable ambienttemperatures and the hydraulic oil used. The cables must berouted into the terminal housing through a fitting cable gland in or-der to ensure compliance with the required type of protection. Thecable must be installed properly in accordance with the require-

ments.


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Ensure equipotential bonding of the machine or system. A corre-sponding connection option is provided and marked accordinglywith a symbol.

PE conductors must be connected.

Cable shields must be provided in accordance with EMC require-ments (or according to the customers specifications).

EN 60204-1 must be observed! In addition, local legal stipulationsand standards as well as other applicable special regulations mustbe observed.

WARNING!Electrical shock! Cabling work may only be carried out bytrained electrical specialists observing common safety regula-tions.

Caution:

Incorrect connections can result in destruction of the valuable elec-tronics or in uncontrolled movements in conjunction with the acti-vated hydraulic system.

The closed control loops may only be put into operation by spe-cialist personnel with the relevant qualification.

Incorrect connections can result in excessive housing voltage andhigh discharge currents.

Danger to life due to shock currents

Risk of injury due to electrical shock

Risk of injury due to burning

To avert risks caused by electric current, at least the followingsafety rules must be observed:

1. Safety disconnection

2. Secure against unauthorized reclosing:

3. Make sure that the system is de-energized

4. Cover or fence off neighboring live parts

5. Ground and short-circuit

6.5 Commissioning the electrohydraulic actuator

Before commissioning, read the safety regulations in chapterFehler! Verweisquelle konnte nicht gefunden werden."Generalsafety regulations". Follow the instructions given there.


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Work on hydraulic components may only be carried out by special-ist personnel having specific knowledge and experience in the fieldof hydraulics!

Work on electrical components may only be carried out by special-ist personnel having specific knowledge and experience in the fieldof electrics!

How to commission the electrohydraulic actuator:

Check that all pipes and components are correctly connectedaccording to the installation drawing / circuit diagram.

Verify that all flanges and fittings are properly tightened.

WARNING!

Oil jets of hydraulic oil caused by incorrect connection of hy-draulic pipes!

Hydraulic oil escaping under high pressure and parts flying a-round can cause serious injury!

Before carrying out tests check the hydraulic pipes for proper fit.

Make sure that nobody stays in the direct vicinity of the elec-trohydraulic actuator while tests are being carried out.

If required, get these persons to leave the danger zone. Stopthe test, if necessary.

In the case of position transducers mounted at the side, the

protective sheet must not be removed.

Apply pressure to the pressure port of the supply pipe (port X1(P). Start with low pressure.

Verify that the electrohydraulic actuator, the hydraulic connec-tion and hydraulic pipes are leak-free.

Immediately remedy any detected defects.

If applicable, connect electrical control accessories.

Bleed the electrohydraulic actuator. As far as required, the ac-

tuator chambers can be bled via the minimess ports at both ac-tuator chambers. Work carefully.

Test the actuator for function.

The functions provided are indicated on the hydraulic circuit dia-gram.

Immediately remedy any detected defects.

Repeat the functional test, if necessary.

If required, adjust the limit switch position. Do not remove anyprotective panels. Exception: Control actuators of the extending


36/265



type (position transducer fitted at the side and limit switch typeGO switch). Work carefully.

Make sure that the steam control valve or steam trip valve fittedclose absolutely leak-free and there is no other leakage. This

must be tested by a suitable leakage test and be documented.

If no deficiencies are detected and the valve closes leak-free,the electrohydraulic actuator can be commissioned.


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Operation 7


7 Operation

7.1 Normal operation

During normal operation, no interventions by the operator are re-quired directly on the electrohydraulic actuator.

The electrohydraulic actuator is open or closed-loop controlled viathe control and instrumentation equipment of the customer.

Note: Please note that the servo-valve requires a superim-posed dither signal.Recommendations with regard to frequency and am-plitude can be found in the data sheet of the servo-valve.Frequency and amplitude must be optimized to therelevant application.The servo-valve must not assume safety functions(exclusively control function).


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7 Operation


Own notes


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Inspection and maintenance work 8


8 Inspection and maintenance work

This chapter describes inspection and maintenance work that must

exclusivelybe carried out by specifically trainedand qualifiedpersonnel.

8.1 General

Before carrying out any maintenance work, read the safetyregulations in chapter Fehler! Verweisquelle konnte nicht gefun-

den werden.General safety regulations. Follow the instruc-tions given there.

Work on hydraulic components may only be carried out by special-ist personnel having specific knowledge and experience in the fieldof hydraulics!

Work on electrical components may only be carried out by special-ist personnel having specific knowledge and experience in the fieldof electrics!

DANGER!Hydraulic oil squirting out!

Hydraulic oil squirting out under high pressure can penetrate theskin or cause severe injuries.

Before disconnecting system sections that have to be opened,switch the system off, depressurize and protect it against re-starting!

Settings for pressure switches and pressure relief valves are givenon the relevant hydraulic circuit diagrams and drawings.

Immediately report any faults detected in order that they canquickly be rectified. Take into account that small defects canturn into major defects, if they are not rectified in due time.

Notes on adjustments


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Never use the following for cleaning:

Benzene or other, easily inflammable substances

Compressed air (dirt can get into sensitive parts of the electro-hydraulic actuator)

High-pressure cleaner (dirt and humidity can get into sensitiveparts of the electrohydraulic actuator)

Large amounts of water or cleaning agents

Lint-free and clean floor cloths or rags (if required, wetted).

Common cleaning agents

Cleaning aids


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8.2 Inspection and maintenance schedule

The table below lists the individual activities sorted by maintenanceintervals and by assemblies/components.All maintenance and repair work must be documented.

When? Where? What? Remarks

Hydraulic componentsof the electrohydraulicactuator

Every 3months

Hydraulic pipes andfittings

Visual inspection Leakage must be immediatelyeliminated.

Remove parts that lie around.

Spilled fluid must be immediatelyremoved. Risk of slipping!

Electrical connections,cables,plug-in connectors andsockets, power cables

Visual inspection If damaged, have them replacedimmediately. Ensure correctmounting.

Visual clogging indica-tors on filters

Visual inspection When the visual clogging indicatoron a filter responds, the filter ele-ment is clogged and must be re-placed.

Every 6months


Hydraulic pipes andfittings




Terminal box, electricalconnections, cables,plug-in connectors andsockets, power cables

Visual inspection If damaged, have them replacedimmediately.

Ensure correct mounting.

Visual clogging indica-tors on filters

Visual inspection When the visual clogging indicatoron a filter responds, the filter ele-ment is clogged and must be re-placed.

All components Clean dirty parts (if required,

remove any accumulated dust)

Wipe off oil immediately usinga cloth.

This simplify the detection of leak-

age and its observance.

Continued on next page


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When? Where? What? Remarks

Every 24months(not later than

every 36months)

Filters Change filter elements

Poppet, directional andservo-valves (as far asinstalled)

Check of- switching times- function

Position transducers Functional check

Limit switches Functional check

Hydraulic pipes Check all pipes and fittings forleakage and externally visibledamage!

Have any damage immediatelyrepaired!

Splashing oil can cause inju-ries!

Initiate the immediate replacementof hydraulic pipes in the case of:

- damage

- leaky spots





Electrical connections,

cables,plug-in connectors andsockets, power cables,all electrical devices

Visual inspection In the case of damage (or appar-

ent signs of aging) have themimmediately replaced.

Ensure correct mounting.

Disk spring column,spring forces and guides(as far as provided)

Check for proper function

Inspection and maintenance

Take note of traces of corrosion.In the case of severe corrosion,replace.

The spring package may only bechanged at the manufacturersend!

Clogging indicators Visual inspection

Possibly functional check

Every 5 years,but not laterthan every 6years

All seals Change seals Seals may only be changed atthe manufacturers end!

In addition, same sco-pe as

Every 24 months

In addition, same scope asEvery 24 months

In addition, same scope as Every24 months

Table 8.1: Inspection and maintenance schedule


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8.3 Maintenance work on the electrohydraulic actuator

The complete maintenance work and repairs must be carried outby the manufacturer or specifically trained (by the manufacturer)personnel and the work carried out must be documented(see chapter 8.2).

Spare parts must meet the technical requirements laid down by the

manufacturer. This is ensured when genuine spare parts are used.

Only genuine spare partsmay be used and their use must beproven (documented).

Spare parts can be ordered from Bosch Rexroth stating the detailsgiven in the parts and spare parts lists.

For carrying out the work, you require:

usual fitters tools

floor cloths

Spare parts

Tools and aids


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Own notes


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Service addresses 9


9 Service addresses

9.1 Service points in Europe

Bosch Rexroth AG

Service Automation

Brgermeister-Dr.-Nebel-Str. 8

D-97816 Lohr am Main

Tel.: +49 (9352) 18-1164

Fax: +49 (9352) 18-3363

9.2 Service points in America

Bosch Rexroth Corp.

Service Automation

2315 City Line Road

Bethlehem, PA 18017-2131

Tel.: +1 (610) 694- 8453Fax: +1 (610) 654- 8670

9.3 Service points in Asia

Bosch Rexroth Corporation

Service Department

Tsuchiura Head Office and Plant

5 1, Nakanuki-machi,

Tsuchiura-shi, Ibaraki-ken, 300-8588, Japan

Tel.: +81-(0)29-834-8151Fax: +81-(0)29-834-8150


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10 Waste disposal


10 Waste disposal

The springs on the electrohydraulic actuator are pretensioned. Riskof injury! The housing with integrated manifold may only be openedusing special tools. If required, consult the manufacturer to obtainmore detailed information.

The actuator should only be disposed of by a certified disposalcompany in accordance with applicable laws and regulations.

Note: Take note of residual oil!Waste / non-recyclable waste / hazardous substancesmust be disposed of according to their relevant type.


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Bosch Rexroth AGZum Eisengieer 1D-97816 Lohr am MainTelefon +49 (0) 93 52/18-0Fax +49 (0) 93 52/18-1040

www.boschrexroth.de


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Item No. Ident No. Qty. Description Type

BOSCH REXROTH

BRH/ESL Hydr.Antriebstechn. - Zum Eisengieer 1 - 97816 Lohr am Main - Phone 09352/18-117

PARTS LIST FOR HYDRAULIC CIRCUIT NO.: HS-A11-N674- Key word: Docu.BHEL -

Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005

Cust omer : Bharat Heavy El ect r i cal s Lt d.

Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orHPCV STV 160- 177 ( MAA12)

100 R901186386 1 HYDRAULI C CYLI NDER CGE1MF3/ 140/ 60/ . . 65F. 020 R901193252 1 PRESSURE FI LTER DRUCKFI LTER DF. 021 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD. 030 R900716661 1 PRESSURE FI LTER DRUCKFI LTER DF. 031 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD

. 040 R900772317 1 HY- SERVOWEGEVENTI L 4WS2EM10- 5X/ 60B11T315. 050 R900929926 1 HY- LOGI C CARTRI DGE VALVE LC 32 A40E7X/ V

. 051 R900965932 1 HY- LOGI C COVER LFA 32 WEA27- 7X/ V

. 060 R900929926 1 HY- LOGI C CARTRI DGE VALVE LC 32 A40E7X/ V


. 052 R900212093 1 HY- POPPET DI RECT VALVE DI RECT OPERATED M- 3SEW 6 C3X/ 420MG25N


. 070 R900012297 1 SCREW PLUG VERSCHLUSSSCHRAUBE G





. 080 R901197075 1 OI L PAN OELWANNE 846X 360X 4

. 081 R900204613 1 PROXI MI TY SWI TCH NAEHERUNGSSCHALTER CB


81/265


BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orHPCV STV 160- 177 ( MAA22)

200 R901186386 1 HYDRAULI C CYLI NDER CGE1MF3/ 140/ 60/ . . 65F. 020 R901193252 1 PRESSURE FI LTER DRUCKFI LTER DF. 021 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD. 030 R900716661 1 PRESSURE FI LTER DRUCKFI LTER DF. 031 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD

. 040 R900772317 1 HY- SERVOWEGEVENTI L 4WS2EM10- 5X/ 60B11T315. 050 R900929926 1 HY- LOGI C CARTRI DGE VALVE LC 32 A40E7X/ V














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BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orI PCV STV 360- 45 ( MAB12)

300 R901186387 1 HYDRAULI C CYLI NDER CGE1MF3/ 140/ 60/ . 125F. 020 R901193252 1 PRESSURE FI LTER DRUCKFI LTER DF. 021 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD. 030 R900716661 1 PRESSURE FI LTER DRUCKFI LTER DF. 031 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD

. 040 R900711077 1 SERVO DI RECTI ONAL VALVE 4WS2EM10- 5X/ 90B11T315. 050 R900929926 1 HY- LOGI C CARTRI DGE VALVE LC 32 A40E7X/ V














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BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orI PCV STV 360- 45 ( MAB22)

400 R901186387 1 HYDRAULI C CYLI NDER CGE1MF3/ 140/ 60/ . 125F. 020 R901193252 1 PRESSURE FI LTER DRUCKFI LTER DF. 021 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD. 030 R900716661 1 PRESSURE FI LTER DRUCKFI LTER DF. 031 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD

. 040 R900711077 1 SERVO DI RECTI ONAL VALVE 4WS2EM10- 5X/ 90B11T315. 050 R900929926 1 HY- LOGI C CARTRI DGE VALVE LC 32 A40E7X/ V














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BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orHP - SSV 200- 177 (MAA11)

500 R901186383 1 HYDRAULI C CYLI NDER CGE1MF3/ 140/ 60/ . 100F. 020 R901193252 1 PRESSURE FI LTER DRUCKFI LTER DF. 021 R901193256 1 CLOGGI NG I NDI CATOR VERSCHMUTZ- ANZEI GE VD. 030 R900767230 1 COVER PLATE HSA 99- 28086- ZA/ V00- D. 040 R900570174 1 HY- POPPET DI RECT VALVE DI RECT OPERATED M- 3SEW 6 U3X/ 420MG24N

. 042 R900156650 1 NOZZLE DUESE 2,. 043 R900156650 1 NOZZLE DUESE 2,















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BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orHP - SSV 200- 177 (MAA21)

















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BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orI PSV SSV 400- 45 ( MAB11)

















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BOSCH REXROTH



Name

Orig.:

Processor:

Quot at i on No. : UH01- 0804- 5313- B

Or der No. : 0000900005


Wei s ( SCL)

Wei s ( SCL)

El ect r ohydr aul i c act uat or EHA4 f orI PSV SSV 400- 45 ( MAB21)

















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1/682-way cartridge valvesDirectional functions

Cartridge valves and control covers

Types LC and LFA

Sizes 16 to 160Component series 2X; 6X; 7XMaximum operating pressure 420 barMaximum flow 25000 L/min

RE 21010/03.05Replaces: 02.03

Cartridge valve type LC 25 A40E7X/Control cover type LFA 25 WEA-7X/with directional valve type 4WE 6D6X/EG24N9K4 and cable socket

H5455H5591

Table of contents

Contents see page 2

Features

Valve poppet with or without damping nose

2 area ratios

4 different springs

4 stroke limiters

Control cover with integrated poppet valve

Control cover with integrated shuttle valve

Control cover for mounting directional spool valves with orwithout integrated shuttle valve

Control cover with or without limit switch monitoring Further information:

Pilot control valves Size 6 Size 10

Directional spool valve type WE RE 23178 RE 23327

Directional poppet valve type SEW RE 22058 RE 22075

Directional poppet valve type SED RE 22049 RE 22045


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2/68 Bosch Rexroth AG Hydraulics LC; LFA RE 21010/03.05

Table of contents

Contents Page

Features 1

Function, sections, symbol 3

Mounting cavity and connection dimensions 4, 5

Technical data 6

Cartridge valve type LCOrdering code 7

Preferred types 7

Symbols 7

Technical data 8

Characteristic curves 9

Contents Page

Control cover type LFAGeneral notes on the ordering code 10, 11, 16

Preferred types 11

Basic symbols 12, 13Characteristic curves for the selection of nozzles 14

Material numbers of nozzles and plug screws 15

Fixing screws 16

Symbols and unit dimensions:

Type ..D 17, 18

Type ..H 19 to 21

Type ..G 22, 23

Type ..R; ..RF 24, 25

Type ..R; ..R2 26, 27

Type ..WEA, ..WEB 28 to 33

Type ..WEMA, ..WEMB 34 to 37

Type ..WEA8, ..WEB8 38, 39

Type ..WECA 40 to 42

Type ..WEA9 43

Type ..GWA, ..GWB 44 to 49

Type ..KWA, ..KWB 50 to 55

Type ..E 56, 57

Type ..EH2 58, 59

Type ..EWA, ..EWB 60 to 65

Inductive position switch type QM 66

Cable socket for inductive position switch type QM 66


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B

A

X

1

4

3

2

86

5; 7A1 100%

A2 7% (50%)

A3 107% (150%)

B

A

X

1

3

2

8

6

5; 7A1 100%

A2 7% (50%)

A3 107% (150%)

Hydraulics Bosch Rexroth AGRE 21010/03.05 LC; LFA 3/68

Function, sections, symbol

2-way cartridge valves are designed as elements for insertioninto compact blocks. The power part with ports A and B is in-stalled in a mounting cavity, which is standardised accordingto DlN ISO 7368, in the block and sealed by means of a cover.In most cases, the cover forms at the same time the connec-

tion between the control section of the power part and the pilotcontrol valves. By controlling the power part with appropriatepilot control valves, it can perform pressure control, directionaland throttling functions or a combination of these. Particularlyeconomic solutions can be achieved by adapting the sizes tothe different flows in the individual channels of an actuator. Avery cost-efficient solution can be obtained, if several functionsare assigned to the power part of an element.

Directional function

2-way cartridge valves mainly consist of a control cover (1) anda cartridge element (2). The control cover is provided with pi-lot bores and, depending on the required overall function, op-tionally a stroke limiter, a hydraulically controlled directional

poppet valve or a shuttle valve. Moreover, electrically oper-ated directional spool valves or directional poppet valves canbe mounted onto the control cover. The cartridge consists of abushing (3), a ring (4) (up to size 32 only), a valve poppet (5),optionally with damping nose (6) or without damping nose (7)and a closing spring (8).

Function

2-way cartridge valve operate in dependence upon pressure.Three pressurised areas are essential for the function: A1, A2,A3. The area of the valve seat is always taken as 100%. As aresult of the stepping, the annulus area A2 is 7% or 50% ofarea A2, depending on the version. Consequently, the area ra-tio A1: A2 is either 14.3:1 or 2:1. Area A3 is equal to the sum

of areas A1 + A2. Due to the different area ratios A1: A2 andthe resulting different annulus areas (A2), area A3 is either107% or 150% of area A1 on the seat that is assumed to be100%.

The following is generally valid:

Areas A1 and A2 act in the direction of opening. Area A3 andthe spring act in the direction of closing. The effective directionof the force resulting from the opening and closing forces de-termines the spool position of the 2-way cartridge valve.

The medium can flow through 2-way cartridge valves from A toB or from B to A. When area A3 is pressurised due to the pilotoil flow from channel B or external pilot oil supply, channel A isleak-free closed.

Sizes 16 to 32

Sizes 40 to 160

Type LFAD../FX..

Type LC..A

..E

../..B D

X X**

B

A

X


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9; 10

450,2

2150,2

2150,2

600,2 9; 1012 x M42; 74

400

0

,3

480

45

45

22

,5

45

45

22

,5

X

Y1

Y

5

5

R0,2 max.

62H11

R1

4,

5+0,1

40 max.(X, Y, Y1)

Rz1max 8 U Rz 20L Rz 12

Ptmax 20

L1

L20,2

L50,2D7H13; 10 4 x D5; H4

L20,2L

30,2

L40,2

L1

L40,2

L40,2L40,2 D6 max.(X, Y, Z1, Z2)

x Y

Z1

Z2

5

6

45

45

22,5

9; 10300,2

1650,2

1650,2

9; 10450,2

3000,3

380

32 max.(X, Y, Y1)

8 x M36; 62

5

X Y

5

Y1

Z1

Z2

AD1H7

WT

H8 1

5

H1(H1*)

D3(D3*)

15

H9

A

B

D2

D4H7

H7

H6

H5

H30,1

H2+0,1

A0,05

Y

7 1

7 13 2 4

X

Z

Y

Z

=

=

=

X

Y

Z

Rz1max 4

Rz1max 8

Rz1max 10

D7H13; 10

8 x D5; H4

D6 max. L20,3

L1X Y

Z2

Z15

(X, Y, Z1, Z2)

35 22,5

45

4/68 Bosch Rexroth AG Hydraulics LC; LFA RE 21010/03.05

Size 125

Sizes 80 and 100

Size 160

For indication of dimensions and explanation of positions,see page 9!

Mounting cavity and connection dimensions to DIN ISO 7368 (except for sizes 125 and 160)(nominal dimensions in mm)

Size 16 to 63


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Hydraulics Bosch Rexroth AGRE 21010/03.05 LC; LFA 5/68

Mounting cavity and connection dimensions to DIN ISO 7368(except for sizes 125 and 160)(nominal dimensions in mm)

1 Depth of fit

2 Reference dimension

3 For diameters other than D3 or (D3*) for port B, thedistance from the cover support surface to the centreof the bore must be calculated.

4 Port B can be arranged around the central axis of portA. However, care must be taken to ensure that themounting cavities and the pilot bores are not damaged.

5 Drilling for locating pin

6 Note on porting patter for size 16: Length L1 (xy axisof bores) for control cover with built-on directionalvalve is 80 mm.

7 For 45 mm fit H8 permitted!

1)Maximum dimension

Size 16 25 32 40 50 63 80 100 125 160

D1 32 45 60 75 90 120 145 180 225 300

D2 16 25 32 40 50 63 80 100 1501) 2001)

D3 16 25 32 40 50 63 80 100 125 200

(D3*) 25 32 40 50 63 80 100 125 150 2501)

D4 25 34 45 55 68 90 110 135 200 270

D5 M8 M12 M16 M20 M20 M30 M24 M30

D61) 4 6 8 10 10 12 16 20

D7 4 6 6 6 8 8 10 10

H1 34 44 52 64 72 95 130 155 192 268

(H1*) 29.5 40.5 48 59 65.5 86.5 120 142 180 243

H2 56 72 85 105 122 155 205 245 300+0.15 425+0.15

H3 43 58 70 87 100 130 1750.2 2100.2 2570.5 3700.5

H4 20 25 35 45 45 65 50 63

H5 11 12 13 15 17 20 25 29 31 45

H6 2 2.5 2.5 3 3 4 5 5 70.5 80.5

H7 20 30 30 30 35 40 40 50 40 50

H8 2 2.5 2.5 3 4 4 5 5 5.50.2 5.50.2

H9 0.5 1 1.5 2.5 2.5 3 4.5 4.5 2 2

L1 65/80 85 102 125 140 180 250 300

L2 46 58 70 85 100 125 200 245

L3 23 29 35 42.5 50 62.5

L4 25 33 41 50 58 75

L5 10.5 16 17 23 30 38

W 0.05 0.05 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.2


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Rexroth Manual for Actuators

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