Pressure reducing station R417000844 R417000845 R417000888

Operating instructions

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

Included are instructions and technical drawings, which may not be reproduced or copied either in part of whole, nor may they be used for evaluation or distributed for competition purposes.
The diagrams and drawings used in this manual are for guidelines only and are not to be used for the actual design. This edition supersedes all previous ones. No part of this edition may be reproduced whithout our prior permission. Order Number: 883 890 035 3 BDL 001 AC

Table of contents
Safety information Explanation of symbols Occupational safety Design and mode of operation General Block diagram Versions Startup Ports and Installation, Assembly position, Maintenance and care General Replacing the sealing elements, dismantling Dismantling the filters and the drain valves Dismantling the pressure switch and the adjusting screw Dismantling the pressure control valves Dismantling the three/two-way valve Replacing the sealing elements, assembly Setup and Tests Spare parts package Storage and transportation General Technical specifications General Circuit diagram Dimensional drawing After sales service and adresses Any questions? 28 28 29 30 30 32 33 34 34 35 35 36 36 38 38 40 42 43 44 45 45 46 46 46 47 48 48

GB

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Safety information
Danger! This symbol is to be found with all information and warnings in these operating instructions regarding work safety, where there is potential danger to humans. Take notice of such warnings and act with particular caution in these cases.

Explanation of symbols

Warning!

Warning! This symbol is to be found in these operating conditions wherever it is necessary to ensure that guidelines, regulations and warnings are adhered to and that the work processes are carried out correctly, without damage to or destruction of the servo-actuator.

This way up! This symbol is found wherever components have to be transported, stored or mounted in a particular position. (to DIN 30 600)

Fett Grease

Grease! This symbol is to be found wherever components, areas etc. need to be lubricated.

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

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Safety information
Warning

Occupational safety

Do only pressurise the pressure-reducing station, if it has been mounted properly. Do not handle the pressure-reducing station, if it is pressurised. Always cut off the air supply before starting work.

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

Proper Use
The pressure-reducing station has the following purpose: Reduction of a high inlet pressure to a low outlet pressure. The ambient conditions as well as the operating pressure range specified in the technical data have to be observed. The compressed air supplied must be clean, dry and free of lubricant. Air quality: Quality class acc. to : Solid matters Oil rate Pressure dew point PNEUROPrecommendation 6611 / 1984 4 3 2 ISO 8573-1 7 3 3

Applications other than those stated are regarded as not appropriate. Improper use is at the customer's risk. The manufacturer is not liable for any resulting damage. This device may cause danger if it is used improperly, under inappropriate conditions or by unqualified personnel. Using the device appropriately does, of course, also mean observing the assembly, dismantling and maintenance instructions.

Guarantee
The pressure-reducing station must by maintained and repaired by authorised, skilled personnel only. The user must only operate the pressure-reducing station in perfect condition. The user is obliged to report any changes of the device's condition that might reduce its safety. Unauthorised modifications and changes that might reduce the safety of the pressure-reducing station are not permitted. Before commissioning please read the operating instructions carefully.

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Design and mode of operation

Purpose
The pressure-reducing station has the following purposes:

General

Filtering the pressurized air and condensing Reduction of a high inlet pressure to a low outlet pressure Monitoring of the reduces outlet pressure via pressure gauge and safety valve Ventilation of the compressed air tab A.

Design
The pressure-reducing station consists of a housing that contains the following components (fig. 1) : compressed air filter with drain valve (1), pressure control valves (2), safety valve (3), pressure gauge (4), 3/2-way valve, operated electromagnetically (5) and pressure switch (6) with testing tab (7).

Mode of operation
The pressurized air entering at point P (pmax = 30 bar) flows through the compressed air filter (1) and is cleaned from solid impurities. The resulting condensate is collected in the lower part of the housing and may be drained via the drain valve. The cleaned, pressurized air then reaches the pressure control valve (2). Here the reduction from the inlet pressure to a lower outlet pressure (3 bar...8,5 bar) takes place. The outlet pressure set at the pressure control valve is indicated at the pressure gauge (4). The safety valve (3) has to limit the operating pressure in the pressurereducing station to a maximum of 8,5 bar in order to prevent damages to the connected devices. The compressed air continues to flow from the pressure control valve (2) to the electro-magnetically operated 3/2-way valve (5). This valve can supply the tab A with compressed air. In addition to tab A tab P1 also furnishes a constant compressed air supply.

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

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Design and mode of operation

If the compressed air supply at tab P is interrupted, the pressurereducing station is vented by force; thus ensuring that no pressure is present at any of the subsequent devices. (cf. block diagram on page 32 and circuit diagram on page 46)

General

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

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Design and mode of operation

Blockdiagram
fig. 1

P1

14 P
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Design and mode of operation

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

Versions

pressure gauge

drain valve 3/2-way-valve

safety valve

pressure switch

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

pressure gauge

drain valve

3/2-way-valve safety valve

pressure switch

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Startup

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

Versions

drain valve 3/2-way-valve safety valve

pressure switch

Ports and Installation

Ports and Installation

The pressure-reducing station is fixed with 3 screws M10. The boring pattern can be taken from the dimensional drawing. Pneumatic connections are materialised by traded ports M14x1.5.

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

Warning!

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

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Maintenance and care

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

General

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

Warning!

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

Cleaning of the filter cartridge

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

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

Warning!

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

Replacing the filter cartridges

Extremely dirty filter cartridges should be replaced by new ones. The required parts are contained in the spare parts package 335 320 003 2.

Fett Grease

Greasing the sealing elements

The sealing elements of the pressure-reducing station have to be greased lightly using the lubricant contained in the repair set before assembly, except if they are subject to special maintenance and care instructions. Before assembly, all sealing seats, faces etc. have to be cleaned.

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Maintenance and care

Dismantling

Replacing the sealing elements, dismantling

The following section describes the dismantling and assembly of a pressure-reducing station for the replacement of the sealing elements. All elements necessary for a complete scheduled overhaul are contained in the spare parts package 335 320 003 2. In case of such an overhaul, the following instructions for the dismantling/mounting have to be adhered to.

Warning!

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

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

Loosen fastening screw T1 and remove sealing ring 1, filter 2 and O-ring 3 Remove valve screw T2 and sealing ring 4 Remove circlip 7 and spring 6 as well as valve 5 from the valve screw T2.

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Maintenance and care

fig.3

B C

1 2 3 T1
MA = 150Nm

Y X

C T26 T25

T11 7 6 5 4 T2
MA = 60Nm

26

view Y

view X

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Maintenance and care

Dismantling the pressure switch (fig. 4a) (Version R417000888 , R417000844 , 3353202000 and 3353202020)
Disassemble pressure switch T3. Loosen screw T4 (2x) Remove O-ring 36

Dismantling

Dismantling the pressure switch (fig. 4b) (Version R417000845 and 3353202010)
Disassemble pressure switch T3. Loosen screw T4 (2x) Disassemble adapter T12 and screw T24 (2x) Remove O-ring 11 and 36

Dismantling the pressure control valves (fig. 5)

Loosen grub screw T7 and remove cap T8 from the housing Remove spring T9 and piston 35 with O-ring 14 Disassemble circlip 15 and pull valve 16 together with valve nut 17, bushing 18, valve ring 19, O-ring 21 and O-ring 34 from the drill hole. Remove spring 20 Dismantle circlips 22, 24 and filters 23, 25 Remove banjo bolt T11 from the housing and remove piston cup 26 (cf. fig. 3).

Dismantling the adjusting screw (fig. 4a)

Disassemble circlip 12 and remove washer T5 Remove adjusting screw T6 from the housing. Remove O-rings 8, 9 and 10 Remove ventilation 13.

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Maintenance and care

fig.4a

13
fig.4b

T5 12 T6

8 9 10 36

T3 T4 11 T12
fig.5

T3

T4

36

T24

T8 T7 T9 35 14

24 25 X 23 22
13.6 +0.2

9.8

37 17 16 15 18 34 20 21 view X

B-B
19
Take care of mounting position !

view Y
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Maintenance and care

Dismantling

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

Loosen screw T25 and remove holding plate T26 (fig. 3) Dismantle servo valve 33. In order to do so, remove ventilation T13, the coil T14 and loosen the screw T15 (2x) Remove gasket 27 Loosen screw T16 (2x) and remove the base plate T17

Warning!

Warning! compression spring T18 is pre-stressed Disassemble the following parts: compression spring T18, bushing T19, piston T20, sleeve T21, ram T22, washer T23 (6x), washers 32, spacer T24 (2x), sealing ring 28 (4x) as well as grooved ring 29 Disassemble circlips 24, 30 and filters 25, 31.

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Maintenance and care

fig.6

C-C

T16 T17

X Y D D

25 24 30 31

T15 33 T14 T13 MA = 1.2 +0.2 Nm

T18 T19

32 T23 28 T24 28

D-D

27

X
T22 28 T23 T24 28 32 T21 T20 29

Y
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Maintenance and care

Assembly
Fett Grease

Replacing the sealing elements, assembly

Reassemble the device in reverse sequence. Take care not to damage the sealing elements during assembling. All sealing elements must prior to assembling be slightly lubricated with the grease from the spare parts kit. Before this all sealing surfaces are to be cleaned.

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

Replace sealing ring1, filter 2 and O-ring 3. Tightening torque for fastening screw T1: MA = 150 Nm Replace sealing ring 4, valve 5, spring 6 and circlip 7. Tightening torque for valve screw T2: MA = 60 Nm Replace piston cup 26.

Assembly of the pressure switch and the adjusting screw

(fig. 4) Replace O-rings 8, 9, 10, 11, 36, circlip 12 and ventilation 13.

Assembly of pressure control valve (fig. 5)

Replace circlip 15, valve 16, valve nut 17, bushing 18, valve ring 19, spring 20, O-rings 14, 21, 34 and piston 35.

Warning!

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

Warning!

Warning! Ensure correct assembly position of valve ring 19! Replace circlips 22, 24 and filters 23, 25.

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Maintenance and care

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

Assembly

Replace gasket 27, sealing ring 28 (4x) and grooved ring 29 Replace circlips 24, 30 and filters 25, 31.

Warning!

Warning! Bushing T19 and sleeve T21 must overhang the upper housing edge by 0.4 0.1mm. Attach washers 32 accordingly. Replace servo valve 33

Warning!

Warning! In case of pressure reducing stations with holding plate T26 (new version) during assembly the srew T25 must be fixed by a screw securing means (e.g. Loctite 241). In case of pressure reducing stations without holding plate T26 (old version) the exhaust T13 must be tightened with a torque of MA = 1.2+0.2 Nm and a screw securing means (e.g. Loctite 241) must be applied.

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

Setup and Test

Setup and Tests of the pressure-reducing station

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

Warning!

Warning! Turn cap T8 only in pressureless state. Check the 3/2-way valve for correct performance by working it. Finally the complete pressure-reducing station has to be tested for tightness.

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Maintenance and care

Spare parts package:
Order number 335 320 003 2

Spare parts package 335 320 003 2

Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Description
sealing ring filter O-ring sealing ring valve conical spring circlip O-ring O-ring O-ring O-ring circlip ventilation O-ring circlip valve valve nut bushing valve ring conical spring O-ring circlip filter circlip filter piston cup gasket sealing ring grooved ring circlip filter washer servo valve O-ring piston O-ring adjusting sleeve lubricant

Dimension
36 x 42 x 2 23,3 x 2,4 22 x 27 x 1,5 0,8 x 12,7 x 26,5 15 x 1 6 x 1,5 5 x 1,2 4 x 1,2 6,75 x 1,78 20 x 1 M14 x 1,5 32,9 x 3,5 14 x 1

Qty.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 4 1 1 1 6 1 1 1 1 1 20g

8x9x4 1 x 11,2 x 18,1 5,28 x 1,78 20 x 1,5 20 x 2,3 8,3 x 0,5 8x2 3x8x4 18 x 3 12,8 x 21,2 x 4 30 x 1,2 30 x 2 13 x 0,2 10 x 1,3 6x2

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Storage and transportation

During storage and transportation the pressure-reducing station must in principle be protected against mechanical damage and weather influences. Contacts with aggressive media must be avoided. Compressed air ports must be closed in a way to prevent entry of dirt, humidity and foreign matter. The ambient temperature during storage and transportation must neither drop below -35C nor exceed +80C.

General

Storage

Warning!

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

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

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Technical specifications
General
Technical Data
Permissible medium inlet pressure outlet pressure pressure reducing valve safety valve pressure switch threaded tabs thermal application range compressed air max. 30 bar min. 3 bar / max. 8,5 bar adjusted to 7,5 bar adjusted to 8,5 bar adjusted to 6,0 bar , decreasing M14 x 1,5 273 K 343 K

Circuit diagram
fig. 7

3 5 2 4

P
1 6 7

P1

14

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Technical specifications
Dimensional drawing / Version R417000888
fig. 8

threaded tabs: M14 x 1.5; 12 deep

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After sales service and adresses

Are there any questions left?

any Questions?

If anything is still not clear after reading these operating instructions, please let us know. Your suggestions for improvements are always welcome. If you require any further information, please contact the sales staff in our Marine Technique Division directly or the address below.

Bosch Rexroth AG The Drive & Control Company Marine Technique Ulmerstrae 4 D 30880 Laatzen

Tel.: Fax.:

+49 (0) 511 2136 251 +49 (0) 511 2136 165

e-mail: marinesales@boschrexroth.de Internet: http://www.boschrexroth.de

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